Implementation of Risk Based Inspection Methodology in Managing Integrity of Abadan Refinery Pressurized Production Facilities

摘要

Following successes in applying risk based approach to equipment management in the refining industry, a risk based inspection (RBI) assessment was performed in an atmospheric distillation unit of Abadan Refinery. This paper describes the methodology, analysis and results of a RBI study conducted on all fixed equipments and process piping circuits of this unit, which was the first effort of this kind in Iran. An in-house software was designed and developed by RBI team that can develop a comprehensive inspection program for each equipment item analyzed, following the procedure and guidelines given in API 581 2008 and API 580 resource documents. Once equipment items had been risk ranked and prioritized, a comprehensive inspection program was developed for the facility. This program was based on the risk ranking for each equipment item, as well as the suspected damage/corrosion mechanisms. The frequency and scope of inspections, as well as appropriate NDE techniques, are described in comprehensive inspection plans for each equipment item. This paper summarizes the experiences in developing and implementing a risk based inspection strategy and the value of the RBI approach in terms of its contribution to the company's business drivers. Limitations in conducting some API 581 second edition procedures for calculating probability and consequence of failure and solutions applied are also described. The study has resulted in numerous benefits for the plant, which include safety and compliance issues, cost savings, and focused inspection plans using the latest NDE technology, and will assist management in making informed, defensible operational decisions. Finally, some useful lesson learned are included to prevent common problems from recurring, to stimulate the application of better practice and where possible to prevent or reduce the failure.