Integrating Inspection Data Management System and Risk-Based Inspection into Esfahan Refinery Plant Integrity Management Software

摘要

This paper describes the methodology,analysis and results of a study conducted in Esfahan Refinery to find the pre-requirements and best practices of an effective risk-based inspection(RBI)program.Operators of process plants show more tendencies to conduct RBI programs to conform to regulatory and insurance requirements for plant safety.RBI assessments are also used as a means to prioritize inspections for the next turnaround.The implementation and maintenance of RBI software tools,especially the quantitative approaches,can require a significant percentage of money.On the other hand,the compliance and safety drivers need to be balanced against the cost and time of RBI projects.Inspection data management system,or IDMS,packages have been in use in some refineries to organize the data in a facility's fixed-equipment inspection program.Application of IDMS packages can decrease the time and effort required for implementation of RBI programs.Currently,most operating companies utilize two different software packages for RBI and IDMS functions.Although this is the most common situation,it is far from an industry"best practice."This paper summarizes the experiences in developing and implementing an integrated RBI(following the guidelines given in API 581 2008)and IDMS software packages and the value of this integration in terms of its contribution to the company's business drivers.The results show that once rules and methodologies have been developed to process raw data,the system cost will be limited almost completely to implementation.The significant advantage of this integrated system will be during evergreening process by which the basic data and assumptions are reviewed and updated with changes in IDMS and the RBI analysis will be automatically updated.The study has resulted in numerous benefits for the plant,which include safety and compliance issues,cost savings,instantly updated inspection requirements and plans,and integrated corrosion modeler,minimum required thickness calculator,RBI software,turnaround planning tool,etc.Finally,some useful lessons learned are included to stimulate the application of better practice.