Implementation of the API RP 584 Integrity Operating Windows Methodology at the Gibson Island Ammonia Manufacturing Plant

摘要

A process gas leak outside of the primary reformer caused a serious fire incident at the Gibson Island Works (GIW) ammonia manufacturing plant in Brisbane, Australia. As part of their global reliability improvement strategy, Incitec Pivot Ltd (IPL) selected GIW as a pilot for the pending API RP 584 Integrity Operating Windows (IOW) standard. An all-inclusive review of plant performance was conducted, including a creep remnant life assessment and stress analyses of the primary reformer. This paper presents a safety overview of the GIW facility and presents a case study of how the IOW standard was implemented at the facility. The steps used to mitigate risk and improve the methods used for additional facilities are also covered.