Topic or Session or Module Name
Copyright: Shell Brands International AG 2008
THE SHELL RISK BASED INSPECTION AND SAFETY APPROACH OF PETROCHEMICAL AND GAS INTALLATIONS 1st CEOC International Safety Seminar Seminar, 3rd Feb. Feb 2010, 2010 Brussels Paul Slangen Shell Projects & Technology Netherlands Sub-Brand zone
Contents About Shell Process safety - Asset management Shell h ll Riskk Based d Inspection (S-RBI)* Deliverables Implementation experience
*S-RBI is a Shell trade mark
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Topic or Session or Module Name
Copyright: Shell Brands International AG 2008
SHELL
UPSTREAM BUSINESSES
GROUP ACTIVITIES App. 50 manufacturing & gas sites
DOWNSTREAM BUSINESSES
CORPORATE
SHELL PROJECTS & TECHNOLOGY
Sub-Brand zone
Copyright: Shell Brands International AG 2008
SHELL PROJECTS & TECHNOLOGY Unit created in 2009, merging: • Global Solutions • Technology directorate of Exploration &
Production
• Safety and environment function • Contracting and procurement function
Sub-Brand zone
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Topic or Session or Module Name
Safety is No Harm - Goal Zero - within Shell Work with a valid work permit when required
Conduct gas tests when required
Verify isolation before work begins and use the specified life protecting equipment
Obtain authorisation before entering a confined space
Obtain authorisation before overriding or disabling safety critical equipment
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Do not walk under a suspended load
Do not smoke outside designated smoking areas
No alcohol or drugs while working or driving
While driving, do not use your phone and do not exceed speed limits
Protect yourself against a fall when working at height
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Wear your seat belt
Follow prescribed Journey Management Plan
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Managing Process Safety Bow-Ties are used for: •
the identification and risk assessment of HSE hazards
•
the evaluation and implementation of control and recovery measures and
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to document that major HSE risks have been reduced to as low as reasonably practicable (ALARP). Hazard Hydrocarbons
Threat
Consequence
Barrier
Corrosion
Material
Barrier Barrier Operating Window
Barrier Barrier
Barrier
Inspection
Gas detection
Top Event
Cause Barrier
Threat
Material
Emergency Response
Effect
E l i /Fi Explosion/Fire
Barrier Barrier
ESD
Small fire
Barrier
MOC
Gas detection
Operating Window
Barrier ESD
Barrier Emergency Response
Degradation Loss of containment Scenario
Consequence Small fire
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Link to Manufacturing Work Processes Proactive Processes
Execution Processes
ESP Bow-Tie
ME RCM
Barriers needed
IPF RBI
RRM* RRM Critical Activities needed to maintain barriers
TA EI ESP
Critical activities needed to maintain barriers Emergency Response, MOC, Competency Mgt., Permit to Work, Document Management, HSE Compliance, Contractor Mgt., PPE The linkages between the other work processes is also very important!! *RRM is a Shell trade mark: Risk & Reliability Management ; ME: maintenance execution; TA: turn around; EI: equipment integrity; ESP: ensure safe production
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Shell RBI has a strict definition Is a risk-based decision support process structured and multidisciplinary to determine and document, cost-effectively, The optimum inspection requirements of pressure containing equipment in its operating context and safeguards integrity
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S-RBI requires regular updating (evergreening) Asset Integrity Database
Corrosion Loop Assessment Including IOW*
Initiate Corrective Actions Remnant Life Calculation
Analyse results & Document
Task Execution
Criticality (Risk) Assessment
Confidence Rating Inspection Interval & Tasks
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*IOW: Integrity Operating Window
Assessment of the Criticality (RAM)
CONSEQUENCE CATEGORY
PROBABILITY C CLASS
Susceptibility to Failure Very susceptible to H degradation
Criticality L
MH
H
E
E
M
Susceptible to degradation under normal conditions
L
M
MH
H
E
L
Susceptible to degradation under upset conditions
N
L
M
MH
H
N
Not susceptible under any forseen conditions
N
N
L
M
MH
ECONOMICS (US$)
no/slight damage
minor damage
local damage
major damage
extensive damage
HEALTH & SAFETY
no/slight injury
minor injury
major injury
single fatality
multiple fatalities
ENVIRONMENT
no/slight effect
minor effect
local effect
major effect
massive effect
NEGLIGIBLE
LOW
MEDIUM
HIGH
EXTREME
CONSEQUENCE CLASS
RAM = Risk Assessment Matrix N = Negligible L = Low MH = Medium High H = High
M = Medium E = Extreme 10
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S-RBI is documented & managed Methodology gy
Process
people p p
RRM = process : people : tools = 40 : 40 : 20
Tool
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Deliverables S-RBI 9 Corrosion Control Document per Unit — Corrosion loops (systems) – potential degradation mechanism – integrity operating parameters – RBI study validity window
9 Summary S-RBI analyses — Criticality distribution – Focus on critical equipment and piping – Optimised Inspection Interval – Summary of equipment with intervals < TA interval – High level inspection plan – Follow-up actions and recommendations
9 Shared knowledge and buy-in by stakeholders 9 Auditable process (transparency)
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Implementation experience
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Study based on present knowledge and experience • Evergreen RBI in the run and maintain phase • Progressing insights – failure (degradation) modes – during – inspections and turnarounds – failure and incident investigations • Need for knowledgeable team members and shared experience i ffrom the h industry i d (standards ( d d and d procedures) d )
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Implementation experience
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Actions and recommendations •
Interaction with other work processes, i.e EI, ME, TA, ESP, MOC…..
Competence of RBI facilitators •
RBI knowledge (i.e. API 580, CEN)
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Facilitation skills
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Project management skills
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Methodology skills
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How can CEOC play a role? Inspection and certification bodies •
Standardisation and guidelines
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Certification –
knowledge (i.e. API 580, CEN etc.)
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facilitation skills
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project management skills
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Copyright: Shell Brands International AG 2008
THANK YOU Discover more at www.shell.com or contact:
[email protected]
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