A Semi-quantitative Approach Development for Risk-based Inspection in a Petrochemical Plant

Davood Eskandari; Hossein Charkhand; Abdollah Gholami

doi:10.3889/oamjms.2020.4391

Authors

Davood Eskandari Department of Occupational Health and Safety, School of Public Health and Safety, Shahid Beheshti University of Medical Sciences, Tehran, Iran
Hossein Charkhand Department of HSE, Arya Sasol Petrochemical Company, Bushehr, Iran
Abdollah Gholami Department of Occupational Health, Social Determinant of Health Research Center, Faculty of Health, Birjand University of Medical Science, Iran

DOI:

https://doi.org/10.3889/oamjms.2020.4391

Keywords:

Risk-based inspection, Equipment failure, Semi-quantitative risk assessment, Inspection plan

Abstract

BACKGROUND: Recently, oil and gas industries have focused on risk-based methods to specifically compile inspection, maintenance, and management strategies worldwide.

AIM: The provided method in this study is a management tool to recognize and then prioritize the equipment’s risks and, consequently, propose an inspection plan based on these risks. In fact, it is a risk analysis aspect of an inspection plan for industrial equipment.

MATERIALS AND METHODS: The study is performed on de-ethanizer unit, considering variety of process equipment including distillation tower, exchanger, pressure vessel, drum, and related piping. To initiate the study, first, the risk-based inspection (RBI) team formed, then all required data were gathered and 22 equipment were identified based on the method.

RESULTS: After RBI be performed and risks are estimated, 13.6% of equipment rated on high risk, 63.63% rated on medium risk, and 22.72% rated on low-risk classification. Based on specific risk criteria for equipment, we determined new parameters as inspection level and type of inspection and finally integrated them. As one of the obtained results, the overhaul maintenance of the unit was postponed to a later time and for equipment that should inspect before this year, reduction risk strategy and advance none distractive test defined, and their inspection time also postpone to 2015 from 2012 to 2013.

CONCLUSION: This decision results in saving a shutdown cost, inspection cost, reduction of failure, and increasing of equipment reliability factor. The result of this study will be helpful to assist similar industries improving their risk management plans.

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