Beruflich Dokumente
Kultur Dokumente
de
Projekat:
Saradnja sa Naftnom industrijom Srbije
Collaboration with Petroleum Industry of Serbia
Project:
RiskNIS: Risk management and use of risk-based approaches
in inspection, maintenance and HSE analyses
of NIS a. d. plants
(http://www.risknis.risk-technologies.com/)
RBI
Risk-Based Inspection
Qualitative Risk Assessment
Unit level
Version 2.0,
Status: Intermediate Draft
Risk before
Risk after
Contacts
Executive Summary
The purpose of this document is to present the results of the Qualitative RISK
Assessment on the level of units of 3 NIS Plants (Panevo, Novi Sad, Elemir), thus giving
an overview of the overall criticality of units and benchmarking the units among
themselves. The RBI analysis has covered 60 process and auxiliary units. This report
gives an overview of the results that are still subject to verification.
Applied methodology used for this purpose is API PUBL 581, Risk-Based Inspection Base
Resource Document, 2000 Edition, APPENDIX A-WORKBOOK FOR QUALITATIVE RISK-
BASED INSPECTION ANALYIS, extended to environmental, business and reputation
consequences categories.
This document gives the description of methodology applied, performed activities, results
and conclusions and recommendations.
The results given are in DRAFT status, subject to further verification from the plants.
Some of the assessment is clearly to be judged as unconfirmed, therefore, the relatively
high levels of risks associated with number of units is more due to the unknown data and
conservatism in the approach then to the real situation in the field.
1 7, 9, 14 33 15
A B C D E
CONSEQUENCES
Dati rezultati imaju status DRAFT, odnosno podaci su nepotvreni, a potvrda je planirana
sa predstavnicima postrojenja. Zbog ovih injenica, relativno visoki nivoi rizika odreenih
za vei broj postrojenja je vie rezultat nedostupnosti podataka i konzervativnosti
kvalitativnog pristupa nego to predstavlja realnu situaciju na terenu.
Table of Contents
Contacts 2
List of Acronyms.................................................... 9
Introduction.........................................................10
Results ...........................................................15
References ..........................................................28
Annex 1 Example of Qualitative Workbook in Serbian........ 29
List of Figures
Figure 1 Preliminary results of API Qualitative Analysis with 60 units
........................................................................ 3
Figure 5 Overall Qualitative Risk Matrix for all three NIS Plants (RNP,
RNS, RGE) ....................................................... 16
Figure 6 NIS Overall Damage matrix for all three units (RNP, RNS,
RGE) ............................................................... 16
Figure 7 NIS Overall Health matrix for all three units (RNP, RNS, RGE)
...................................................................... 17
Figure 8 NIS Overall Environmental matrix for all three units (RNP,
RNS, RGE) ....................................................... 17
Figure 9 NIS Overall Business Consequences matrix for all three units
(RNP, RNS, RGE) .............................................. 18
List of Tables
Table 1 Unit Grouping and responsibility matrix .................. 13
Table 2 Unit overview for Qualitative Risk Matrix for all three NIS
Plants (RNP, RNS, RGE) ..................................... 19
Table 3 Unit overview for Qualitative Risk Matrix for RNP ..... 22
Table 4 Unit overview for Qualitative Risk Matrix for RNS ..... 24
Table 5 Unit overview for Qualitative Risk Matrix for RGE ..... 26
List of Acronyms
Acronyms referred in the document are given below. Explanation of these acronyms can
be found from the text, where it is referred. Symbols used in the document are explained
in the text.
Term Definition
API American Petroleum Institute
CoF Consequence of failure
MTBF Mean Time Between Failure
NFPA National Fire Protection Association, USA
NDT Non-destructive testing/inspection
P&ID Process and Instrumentation Diagram
PoF Probability of failure
QRA Quantitative Risk Analysis
RBI Risk Based Inspection: methods to plan, implement and evaluate
inspections using risk based approach
Introduction
In the scope of the Contract for the extension of the project (Phase II), Risk
management and use of risk-based approaches in inspection, maintenance and HSE
analyses of NIS a.d. plants, the Basic Package (see Annex 6 and Annex 7) contains RBI
analysis for 200 pieces of equipment on the qualitative level (level 1), 80 equipment on
the semi-quantitative level (level 2) and 20 pieces of equipment on the quantitative level
(level 3). Compared with the initial equipment count of about 20.000 pieces of equipment
(se Annex 7 of the contract), and in order to maximize the benefit for the client, it has
been decided to perform benchmarking of units on the qualitative level in order to
determine the best candidates for RBI implementation.
To this goal, the methodology described in the API PUBL 581, Risk-Based Inspection Base
Resource Document, 2000 Edition, APPENDIX A-WORKBOOK FOR QUALITATIVE RISK-
BASED INSPECTION ANALYIS has been applied.
The workbook presents the details of the qualitative RBI analysis procedure,.and is used
to determine the Likelihood and Consequence Category for a given unit. Depending on
the nature of the chemicals in a unit, the Consequence Category can be determined
based on the flammable or toxic hazards for the unit. Within the workbook, flammable
consequences are represented by the Damage Consequence Category, since the primary
impact of a flammable event (fire or explosion) is to damage equipment. Toxic
consequences fall under the Health Consequence Category, since their impact is usually
limited to adverse health effects.
In cases when the unit has a number of different process fluids, the workbook exercise is
applied to the worst case from both Damage Consequence Category and Health
Consequence Category, meaning that it is not necessary that in both parts of the analysis
same amounts and natures of fluids have been considered.
Performed activities
In order to be able to perform the given analysis, the following activities have taken place:
7. Definition of units to be covered by RBI analysis and their grouping in Unit Groups
to be distributed for answering, performed during the kick-off meeting for
Feasibility Study on February 23, 2006 and on separate dedicated meetings with
RGE on May 22, 2006, RNP on May 24, 2006 and RNS on May 25, 2006 (See for
exact grouping of data Table 1)
8. Case studies with the team leaders for RGE (May 22, 2006), RNP (May 24, 2006)
and RNS (May 25, 2006), where one unit was completely analyzed for RGE and
RNP, and for all expected inputs and clarifications explained.
10. Individual data assessment with RNP plant unit representatives, mid-July 2007
Figure 2 Web-based tool implementing API 581 Qualitative RBI Workbook (English)
Figure 3 Web-based tool implementing API 581 Qualitative RBI Workbook (Serbian)
Group Responsible
Loc. Group description
summary Delegated
RGE - Procesno
RGE RGE-1 Procesno postrojenje (Process unit) Zdravko Umievi
Postrojenje
S-200 Visbreaking
RNP- S - 200
S-900 Obrada otpadnih kiselih voda (Waste water
RNP - S- 900
RNP treatment) Vladimir Joki
RNP - S - 1500
S-1500 Vazduh (Air)
RNP - S - 1550
S-1550 Sistem zapornog ulja (Oil)
RNP- S 0250
RNP Bitumen & Polimer Bitumen Zoran Todorov
RNP- S - 0290
RNP RNP- S - 2200 S-2200: Vakuumska destilacija (Vacuum distillation) Zoran Prole
Group Responsible
Loc. Group description
summary Delegated
rezervoarom T-2 (Platforming and tank T-2)
U-2700: Pomoni sistem (Auxiliary system)
Goriva - Sekundarno
(Fuel - secondary)
U-2500 Postrojenje za proizvodnja TNG sa pripadajucim
RNS - U-2500
rezervoarima (LPG production and tanks) Mile Zori
RNS RNS U-2600
U-2600 Postrojenje Unibon - Desulfurizacija (Unibon - Boris Bokovi
RNS - 5800
HDS)
U-5800 Postrojenje za obradu sulfidnih voda (Sulphur
water treatment)
Goriva - Primarno
(Fuel - Primary)
RNS - U-2100 U-2100: Atmosferska destilacija sa stabilizacijom
RNS Mile Zori
RNS U2200 (Atmospheric distillation with stabilization)
U-2200: Vakuum destilacija
(Vacuum distillation)
Uljara 2
(Oil section 2)
RNS - HF-400 HF-400: Hidrofiniing (Hydrofiniching)
RNS RNS - HFH-400 HFH - 400: Postrojenje za proizvodnju vodonika Goran Ristovi
RNS - KRB-400 (Hydrogen production)
KRB-400: Sistem baklje sa pripadajuim cevovodima i
opremom (Flare with piping and equipment)
RNS RNS - 0200 Pogon pripreme vode (Water treatment) 0200: HPV Petar Vidovi
RNS - Obrada
Pogon obrade otpadnih voda sa separatorima i pei za
otpadnih voda
RNS spaljivanje mulja Miroljub Ceki
(Waste water
(Waste water treating with separation and mud furnace)
treatment)
Results
Preliminary results of the analysis are shown in the Risk Matrix (see Figure 5) and in
Table 2.
Furthermore, single risk matrices for various consequence categories are shown as
follows:
The summary results for RNP are shown in the Risk Matrix (see Figure 11) and in Table
3
The summary results for RNS are shown in the Risk Matrix (seeFigure 12) and in Table
4
The summary results for RGE are shown in the Risk Matrix (see Figure 13) and in Table
5.
1 7, 9, 14 33 15
A B C D E
CONSEQUENCES
Figure 5 Overall Qualitative Risk Matrix for all three NIS Plants (RNP, RNS, RGE)
1 7, 9, 14, 15 33
A B C D E
CONSEQUENCES
Figure 6 NIS Overall Damage matrix for all three units (RNP, RNS, RGE)
1 7, 9, 14, 15, 33
A B C D E
CONSEQUENCES
Figure 7 NIS Overall Health matrix for all three units (RNP, RNS, RGE)
1 7, 9, 14, 33 15
A B C D E
CONSEQUENCES
Figure 8 NIS Overall Environmental matrix for all three units (RNP, RNS, RGE)
1 7, 9, 14 15, 33
A B C D E
CONSEQUENCES
Figure 9 NIS Overall Business Consequences matrix for all three units (RNP, RNS, RGE)
1 7, 9, 14 33 15
A B C D E
CONSEQUENCES
Figure 10 NIS Overall Reputation consequences matrix for all three units (RNP, RNS, RGE)
Table 2 Unit overview for Qualitative Risk Matrix for all three NIS Plants (RNP, RNS, RGE)
Very
8 RNP -S-2650 3 C D E C C E
High
Very
12 RNP -S-200 4 A E A A A E
High
Very
18 RNP -S-2500 3 C E A D C E
High
Very
30 RNP -S-570 3 A E A A A E
High
Very
31 RNP -S-650 3 A E A A A E
High
Very
32 RNP -S-1300 3 A E A A A E
High
Very
47 RNS -KRB-400 3 C E E B B E
High
Very
50 RNS -U-100 3 B E C C B E
High
Very
51 RNS -U-200 3 B E D C B E
High
Very
52 RNS -U-2100 4 B D E C B E
High
Very
58 RNS -U-2600 3 C E D C B E
High
1 6, 8, 13 32 14
A B C D E
CONSEQUENCES
LoF Damage CoF Health CoF Env. Business Reputation Overall Risk
ID Unit name
Cat. Cat. Cat. CoF COF Cons. CoF Rank
Very
7 RNP -S-2650 3 C D E C C E
High
RNP -RNP -
8 1 A A A A A A Low
Energana
Very
11 RNP -S-200 4 A E A A A E
High
Very
17 RNP -S-2500 3 C E A D C E
High
LoF Damage CoF Health CoF Env. Business Reputation Overall Risk
ID Unit name
Cat. Cat. Cat. CoF COF Cons. CoF Rank
Very
29 RNP -S-570 3 A E A A A E
High
Very
30 RNP -S-650 3 A E A A A E
High
Very
31 RNP -S-1300 3 A E A A A E
High
RNP -Velika
33 2 A A A C C C Medium
kompresornica
4 1, 5, 6 11
L
I
K
E
L
3 3 4, 9, 14, 15, 16 2, 12, 13 7, 10, 17, 21
I
H
O
O
D
2 8, 19, 20 18
A B C D E
CONSEQUENCES
Very
7 RNS -KRB-400 3 C E E B B E
High
Very
10 RNS -U-100 3 B E C C B E
High
Very
11 RNS -U-2100 4 B D E C B E
High
Very
17 RNS -U-2600 3 C E D C B E
High
Very
21 RNS -U-200 3 B E D C B E
High
4
L
I
K
E
L
3 1
I
H
O
O
D
2
A B C D E
CONSEQUENCES
RGE-1 Procesno
1 3 C C C C C C Medium
postrojenje
Presented results so far have DRAFT status, and show considerable number of units
being in the high or critical risk zones. The results are still subject to further verification.
Furthermore, it has been noted that reluctance by assessing the business or reputation
consequences has given unrealistic results, especially in RNP.
It is to be expected that after the complete data is provided for all 60 units, the
situation will change.
References
[1] Contract No: 45/609 of September 8, 2006
[2] API PUBL 581, Risk-Based Inspection Base Resource Document, 2000 Edition
[3] CEN/WS 24 RIMAP draft CWA August 2007