PETRONAS OPU'S PRD API-RBI STUDY
We were engaged for the study of Pressure Relieving Devices (PRD) Risk Based Inspection (RBI) in 2009 through the Technical Service Agreement with PETRONAS Global Technical Solutions (PGTS). PRD RBI study was executed utilizing API RBI software, which follows API 581, Risk Based Inspection Technology standard. API 581 specifies the quantitative approach in determining risk for PRD.
Risk based methodology is recognized as the way forward to ensure PRD integrity & reliability, optimize equipment run-length and to establish standardized methodology among OPUs.
The study is completed in accordance to the API 581 Standard (Risk Based Inspection Technology),
2nd edition September 2008. The calculation is performed using the API RBI software version 8.03. The analysis was accomplished by:
Determine the risk target for Personnel Risk (m2) and Financial Risk ($) based on PRBI Risk Matrix consistence with the Petronas RBI system. Environmental and reputation risk were excluded for this study.
Set the minimum and maximum inspection intervals for all PRDs at 1 and 10 years respectively.
Review the documents database (PRD Technical Datasheet, Inspection Reports, Process Flow Diagram, Protecting Equipment Technical Datasheet, Piping & Instrumentation Diagram and Production Impact).
Analyse the process flow, PRD design, location and settings for overpressure scenario analysis.
The overall risk for PRD is expressed in a quantitative value, either in Area (m2) or Financial ($) based on two modes of failure; Leakage during service and Fail-to-Open on demand for all overpressure scenario.
From the risk-based inspection assessment, an inspection plan was then developed to reduce the risk of items that exceeded the acceptable Risk Target. For items which risk were inherently low at the current inspection program, the inspection could be adjusted and typically could have been prolonged in order to optimize the cost and resources, while maintaining them within the Risk Target.
Several findings were noted throughout this study. All findings are properly documented and specific recommendations are provided to ensure PRD are operating as intended.
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