RP32 3InServiceInspection Manag.

RP 32-3 INSPECTION AND TESTING OF IN-SERVICE CIVIL AND MECHANICAL PLANT-MANAGEMENT PRINCIPLES October 1998

Copyright © The British Petroleum Company p.l.c.

Copyright © The British Petroleum Company p.l.c. All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient's organisation. None of the information contained in this document shall be disclosed outside the recipient's own organisation without the prior written permission of Manager, Standards, BP International Limited, unless the terms of such agreement or contract expressly allow.

BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING

Issue Date Doc. No.

RP 32-3

October 1998

Latest Amendment Date

Document Title

INSPECTION AND TESTING OF IN-SERVICE CIVIL AND MECHANICAL PLANT-MANAGEMENT PRINCIPLES

APPLICABILITY Regional Applicability:

International

SCOPE AND PURPOSE This Recommended Practice gives guidance on the organising and management of Inspection and Testing of In-Service Civil and Mechanical Plant and is for use onshore and offshore. Its purpose is to define organisational responsibilities and procedures based on economical safe practice.

AMENDMENTS Amd Date Page(s) Description ___________________________________________________________________

CUSTODIAN (See Quarterly Status List for Contact)

Inspection Issued by:Engineering Practices Group, BP International Limited, Research & Engineering Centre Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM Tel: +44 1932 76 4067 Fax: +44 1932 76 4077 Telex: 296041

CONTENTS Section

Page

FOREWORD ..........................................................................................................................iii 1. SCOPE .................................................................................................................................1 2. ORGANISATION ...............................................................................................................1 2.1 Management Responsibility ..........................................................................................1 2.2 Management Delegation................................................................................................2 2.3 Organisational Structure ................................................................................................2 2.4 Inspection Function Responsibilities.............................................................................2 2.5 Inspection Staff..............................................................................................................3 2.6 Specialist Services .........................................................................................................3 2.7 External Inspection Bodies ............................................................................................4 3. STAGES OF INSPECTION ...............................................................................................5 3.1 Design .....................................................................................................................5 3.2 Manufacture...................................................................................................................5 3.3 Construction ..................................................................................................................6 3.4 Commissioning..............................................................................................................6 3.5 Operational ....................................................................................................................6 4. CLASSIFICATION AND REGISTRATION ...................................................................7 4.1 Identification..................................................................................................................7 4.2 Classification .................................................................................................................7 4.3 Registration....................................................................................................................7 4.4 Change of Conditions of Use.........................................................................................8 4.5 Plant Modification and Repairs .....................................................................................8 5. FREQUENCY AND EXTENT OF INSPECTION ..........................................................8 5.1 General .....................................................................................................................8 5.2 Class B Equipment ........................................................................................................8 5.2.1 Introduction...............................................................................................8 5.2.2 Allocation of Grades .................................................................................9 5.2.3 Inspection Grades......................................................................................9 5.2.3.1 Inspection Grade 0 .................................................................................9 5.2.3.2 Inspection Grade 1 ...............................................................................10 5.2.3.3 Inspection Grade 2 ...............................................................................10 5.2.3.4 Inspection Grade 3 ...............................................................................10 5.2.4 Criticality Rating Systems.......................................................................11 5.2.5 Determination of Inspection Frequency..................................................11 5.2.6 Extensions...............................................................................................11 5.3 Class C Equipment ......................................................................................................12 5.4 Types of Inspection......................................................................................................12 5.4.1 Initial Thorough Inspection.....................................................................12

RP 32-3 INSPECTION AND TESTING OF IN-SERVICE CIVIL AND MECHANICAL PLANT-MANAGEMENT PRINCIPLES

PAGE i

5.4.2 Subsequent Thorough Inspections ..........................................................13 5.4.3 Sample Inspection ...................................................................................13 5.4.4 Inspection Reviews .................................................................................14 5.5 Inspection Grade Transfers..........................................................................................15 5.5.1 Principles.................................................................................................15 5.5.2 Grade Transfers - Thorough Inspection ..................................................15 5.5.3 Grade Transfers - Sample Inspections ....................................................15 5.6 Special Cases ...............................................................................................................16 5.6.1 Exemptions .............................................................................................16 5.6.2 Replacement Equipment .........................................................................16 5.6.3 Special Design and Construction ............................................................16 5.6.4 Mature Design.........................................................................................17 5.6.5 Deferred Start-up and Intermittent Operation .........................................17 6. INSPECTION REPORTS AND RECORDS ..................................................................18 6.1 Records ...................................................................................................................18 6.2 Statutory Documents ...................................................................................................19 6.3 Reports ...................................................................................................................19 7. REVIEW OF INSPECTION FUNCTION......................................................................20 7.1 Introduction .................................................................................................................20 7.2 Internal Review - Self Regulation ...............................................................................20 7.3 External Review ..........................................................................................................20 TABLE 1 - EQUIPMENT - RECOMMENDED INSPECTION INTERVALS ..............21 APPENDIX A.........................................................................................................................22 DEFINITIONS AND ABBREVIATIONS ........................................................................22 APPENDIX B.........................................................................................................................24 LIST OF REFERENCED DOCUMENTS ........................................................................24 APPENDIX C.........................................................................................................................25 ENDORSEMENT REVIEW PROCEDURE ....................................................................25 C.1 Introduction.................................................................................................................25 C.2 Methodology ...............................................................................................................26 C.3 Set up Study ................................................................................................................27 C.4 Preparation for Study ..................................................................................................29 C.5 Study ...................................................................................................................32 C.6 Action and Follow Up.................................................................................................35 C.7 Plant Item Information Form ......................................................................................36 C.8 Response Form............................................................................................................40 C.9 Fluid Definition Form .................................................................................................41 C.10 Guide phrases/words in matrix format......................................................................43 C.11 Blank examples of PIIF, FDF and RF forms ............................................................45 C.12 Example Review .......................................................................................................51


PAGE ii

FOREWORD Introduction to BP Group Recommended Practices and Specifications for Engineering The Introductory Volume contains a series of documents that provide an introduction to the BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular, the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in the Introductory Volume provide general guidance on using the RPSEs and background information to Engineering Standards in BP. There are also recommendations for specific definitions and requirements. Value of this Recommended Practice This document represents the accumulated management principles that relate to the Inspection and Testing of In-Service Civil and Mechanical Plant, for ensuring a high standard of plant integrity based on economical safe practice. Application Text in italics is Commentary. Commentary provides background information which supports the requirements of the Recommended Practice, and may discuss alternative options. This document may refer to certain local, national or international regulations but the responsibility to ensure compliance with legislation and any other statutory requirements lies with the user. The user should adapt or supplement this document to ensure compliance for the specific application. Principal Changes from Previous Edition Appendix C has been added Feedback and Further Information Users are invited to feed back any comments and to detail experiences in the application of BP RPSE's, to assist in the process of their continuous improvement. For feedback and further information, please contact Standards Group, BP International or the Custodian. See Quarterly Status List for contacts.


PAGE iii

1.

SCOPE This Recommended Practice gives guidance on the organisation and management of inspection and testing of in-service civil and mechanical plant. It is applicable to oil refineries, petrochemical and chemical plant, onshore and offshore production facilities, transmission pipelines and storage and distribution facilities for finished products. It is not applicable to road, rail or sea transportation. It defines organisational responsibilities, procedures for registration, classification, frequency of inspection, reporting and recording for civil and mechanical plant based on economical safe practice and experience in the oil and chemical industries.

2.

ORGANISATION 2.1

Management Responsibility The inspection of equipment, must be given adequate consideration through all stages from initial design through shop manufacture, site fabrication or erection, commissioning and subsequent operation until permanent de-commissioning and disposal. This Recommended Practice assumes that equipment has been designed, fabricated and installed according to codes, standards or specifications approved by BP. It should also be used for guidance for those installations where BP has not been involved in design, fabrication and installation. Where BP has not been involved then management should ensure that design, construction, installation and testing has been carried out to recognised industry standards and codes. It is the responsibility of management at each operating centre to:(a)

Ensure that installed equipment is suitable for its current service and that it is in a safe condition to commission and operate and that documentation to this effect is available.

(b)

Ensure compliance with national statutory regulations applicable to design, operation, inspection, test and certification of equipment.

(c)

Ensure that the inspection requirements as defined by this Recommended Practice are implemented, so that equipment is maintained suitable for operation consistent with the prime requirements of safety, compliance with national statutory regulations and economical operation, in that order of priority.


PAGE 1

2.2

Management Delegation The management of each centre should delegate the responsibility and the authority - for the correct application of this Recommended Practice to those persons or departments most appropriate and with the necessary technical abilities and qualifications. This delegation of responsibility and authority should be in writing.

2.3

Organisational Structure The management is responsible for ensuring that the inspection function is given terms of reference in writing defining the activities for which it is responsible. These terms of reference should ensure that the inspection function is able to offer advice unbiased by pressures from other operational or engineering functions. The inspection function should have direct access to the operating centre senior management for those occasions:-

2.4

(a)

when it is not possible to reach an agreement acceptable to all functional groups,

(b)

when the inspection function considers it necessary to advise the management of critical information affecting the health and safety of personnel or equipment.

Inspection Function Responsibilities The basic responsibilities of an inspection function should be:(a)

To carry out inspection of all equipment in accordance with the requirements of this Recommended Practice, in so far as it is adopted by the operating centre management.

(b)

To classify equipment and allocate appropriate Inspection Grades to that equipment.

(c)

To maintain a register of all equipment, together with detailed and comprehensive records of each item.

(d)

To ensure that adequate notice is given when items of equipment are due for inspection.

(e)

To inform the management of any items of equipment which become overdue for their next inspection and advise on the corrective action to be taken.


PAGE 2

2.5

(f)

To advise the management whenever the inspection intervals of any item of equipment are reduced or if abnormal conditions of corrosion, erosion or other form of deterioration are detected.

(g)

To advise on limiting conditions of pressure or temperature or other conditions of service to which items of equipment may be subjected.

(h)

To verify that repairs, modification or renewals to equipment are carried out to the specified design.

(i)

To have trained, competent and qualified staff to assist in carrying out the duties which are ascribed to it or to secure specialist advice and assistance as necessary to enable it to discharge its responsibilities in a satisfactory manner.

Inspection Staff Inspection Engineers, should be properly trained and qualified and recognised as competent persons for the work which they carry out. The Inspection Body employing such engineers, either an in-house BP Group or a third party Independent Inspection Authority, should demonstrate competence as a body by compliance with the principles of EN 45004: 1995 (or the ISO equivalent); General criteria for the operation of various types of bodies performing inspection. In the UK this should be demonstrated by the Inspection Body being accredited to BS EN45004: 1995 by UKAS (United Kingdom Accreditation Service). For those bodies not presently accredited, progression towards accreditation in a timely manner should be demonstrated. In the EEC the accreditation will be by the appropriate national body which provides accreditation of inspection bodies and should be completed as soon as reasonably possible following the appointment of the accreditation body. In areas outside of the EEC the principles laid down in EN 45004 should be adopted by operating units when developing In-house Inspection Bodies or selecting external bodies. Cross business peer review and assistance from SPR or OTN may be used to confirm compliance.

2.6

Specialist Services From time to time it is necessary to supplement the inspection function with additional personnel to provide either:(a)

specialist technical services,

(b)

additional personnel to cope with periods of peak activity.


PAGE 3

These additional personnel may be from specialist, competent companies or BP personnel from other centres. Personnel from outside the operating centre should be directly responsible to a member of the inspection function who will direct their activities, and be responsible for accepting their reports. All specialist personnel should have recognised qualifications and experience appropriate to their field of expertise. 2.7

External Inspection Bodies In some of the countries in which BP operates, regulations require that examinations are carried out by an external inspection body. Even where there is no statutory requirement, BP may elect to use an external inspection body for such work. The Inspection Body, should demonstrate competence as a body by compliance with the principles of EN 45004: 1995 (or the ISO equivalent); General criteria for the operation of various types of bodies performing inspection. In the UK this should be demonstrated by the Inspection Body being accredited to BS EN45004: 1995 by UKAS (United Kingdom Accreditation Service). For those bodies not presently accredited, progression towards accreditation in a timely manner should be demonstrated. In the EEC the accreditation will be by the appropriate national body which provides accreditation of inspection bodies and should be completed as soon as reasonably possible following the appointment of the accreditation body. In areas outside of the EEC the principles laid down in EN 45004 should be adopted by operating units when developing In-house Inspection Bodies or selecting external bodies. Cross business peer review and assistance from SPR or OTN may be used to confirm compliance.

Where an external inspection body is used, the inspection function will normally be responsible for ensuring:(a)

That management is advised of all requirements for statutory inspection as appropriate


PAGE 4

(b)

That all information relative to the examination is made available to BP.

(c)

That recommendations for repairs, renewals, etc., are adequately discussed and agreed by BP.

In general, the statutory regulations express only the minimum necessary to satisfy legal requirements, and the documentation supplied by an external inspection body following their examination of an item is essentially a certificate that the item examined meets the requirements of the legislation. Sometimes this is insufficient for BP purposes. At the discretion of the inspection function, a BP inspection engineer may supplement the work done by the surveyor acting for the external inspection body in order to obtain more detailed information on the condition of the item in question and to predict future repairs and safe life. 3.

STAGES OF INSPECTION 3.1

Design Inspection requirements for manufacture, fabrication, construction, commissioning and future operations should be considered at the design stage. Each significant item of equipment should at this stage be assigned a criticality rating to cover the non-operational stages, based on the recommendations of BP Group RP 50-1 or other accepted criticality rating system. This rating is used, together with other local factors, when deciding the level of inspection to apply during manufacture, fabrication and construction. In many countries, there are statutory requirements covering the design of pressure vessels, containers, lifting appliances and certain other classes of equipment. Approval of these designs may be by government-approved inspection agencies only.

3.2

Manufacture General inspection and test procedures for new equipment during manufacture are covered in BP Group RP 32-1.

3.3

Construction Guidance for site inspection and testing of new plant during construction is in BP Group RP 32-2.


PAGE 5

Site fabrication usually involves installation of equipment under more onerous and demanding conditions than works manufacture. Appropriate inspection controls are needed to ensure fabrication standards are met. Project teams should co-operate fully with site inspection functions to ensure acceptable standards are being followed and that adequate data and information is being collated for future operational purposes. Deviations from design or specification and any concessions to incorporate such deviations should be fully documented for future reference. 3.4

Commissioning Guidance for inspection and test of new equipment prior to commissioning is covered in BP Group RP 32-2. Pre-commissioning and commissioning procedures should be agreed between BP and the contractor. In the case of projects directed by an operating centre these should be prepared by the operational management. These procedures should cover all requirements and limitations in operating conditions as required by the design. The operation of protective interface and safety devices should be given special attention.

3.5

Operational The degree and frequency of inspection and maintenance of equipment after commissioning depends on many factors, but the prime considerations are health, safety and current criticality. Management also require up-to-date information on plant condition, its rate of deterioration, future repairs or replacements and predicted safe operating life. Periodic inspection must be tailored to suit each item and its particular needs and will include:(a)

Regular planned inspection to ensure safe, reliable and efficient operation.

(b)

Periodic review of operating conditions and external influences to assess their possible effect on previous inspection report conclusions and inspection intervals. Such reviews may involve limited inspection to verify assumptions.


PAGE 6

4.

CLASSIFICATION AND REGISTRATION 4.1

Identification All equipment requiring periodic inspection should be identified by a unique identification number. With the exception of piping systems this should be stamped or otherwise clearly marked on the equipment. A plant register should be maintained and there should be a procedure for updating this register.

4.2

Classification Equipment should be classified as either A (Statutory), B (NonStatutory) or C (Low Risk). Class A includes all items which are subject to fixed period inspection in accordance with national or local regulations. The external or statutory classification will vary from one country to another. Class B includes items not included in the statutory classification, but subject to periodic inspection and review. Class C includes all items not classified as A or B and which are subject to unscheduled inspection and review. Class C covers equipment on low hazard duty whose criticality in terms of safety consequences and operational reliability does not justify a periodic inspection strategy. This equipment should normally be controlled within a routine maintenance programme.

4.3

Registration In addition to the identification of items of equipment individual records shall be maintained for each item. (See Section 6). When an item is registered a file will be opened for that item and shall contain all relevant design and inspection data. This data may be stored electronically. Although paper systems can be used for recording purposes, this should be carried out using a computerised maintenance management system.

4.4

Change of Conditions of Use Where it is proposed to transfer equipment to a different duty the classification of the equipment and the inspection grading must be the subject of review. Where a change of operating conditions is proposed, including changes in design throughput, careful consideration must be given to the possible effects on the equipment


PAGE 7

and the inspection grading confirmed or modified. Adequate consideration should also be given to the effects of the change of duty to associated plant and systems, particularly safety and pressure relief systems. 4.5

Plant Modification and Repairs Any proposed modification or repairs to plant or equipment must be subject to a formal system of approval in which the design, fabrication, inspection and test requirements are considered by appropriate specialists. The operating centre, in conjunction with inspection function, should ensure that the modifications and repairs are carried out in accordance with detailed work instructions and procedures, that full documentation of all technical details is retained in the records systems and that, if appropriate, changes are made to the classification and/or inspection grading of the item. See commentary for 4.3.

5.

FREQUENCY AND EXTENT OF INSPECTION 5.1

General The intervals which may elapse between inspections for Class A equipment shall be in accordance with the relevant statutory regulations. Where such regulations permit flexibility and self regulation in setting intervals the philosophy and intervals recommended for Class B equipment in this Recommended Practice should be followed.

5.2

Class B Equipment

5.2.1

Introduction All non-statutory equipment used in operating centres falls within Class B or Class C. The choice of inspection frequency can be made only by persons who are thoroughly familiar with the equipment and its operating conditions. This RP includes four concepts which are inter-related and from which decisions may be made regarding inspection frequency:(a)

The allocation of Inspection Grades.

(b)

Inspection review procedures.


PAGE 8

(c)

Sample inspection procedures.

(d)

The exemption of equipment from the requirements of this Recommended Practice.

The maximum intervals for the particular Inspection Grade must not be exceeded unless there are sound technical reasons for doing so, noting the special case considerations in 5.6. Such reasons must be clearly recorded in the equipment record file. 5.2.2

Allocation of Grades Equipment in Class B should be subject to scheduled periodic inspection and should be allocated an Inspection Grade 0, 1, 2 or 3 which indicates the maximum interval that may elapse between thorough inspections. (See Section 5.2.5 and Table 1). Some of the factors to be considered when assessing the Inspection Grade to be allocated are:(a)

Severity of service duty and the risk (probability x consequences) of failure of the item.

(b)

Previous history of similar equipment on similar duties.

(c)

The original standards of design, materials and construction.

(d)

The age of the item and the length of time it has been in commission.

(e)

The proper use of components and materials.

5.2.3

Inspection Grades

5.2.3.1

Inspection Grade 0 This is the Grade to which all graded equipment should normally be assigned, following the pre-commissioning inspection and until the initial thorough inspection is carried out. A subsequent Grade is then determined. The recommended maximum interval for Grade 0 may be extended when, in the opinion of the inspection function the maturity of design, the operation conditions and the extent of quality control during manufacture are sufficient to justify extension.


PAGE 9

5.2.3.2

Inspection Grade 1 This Grade should be applied when the conditions of service are such that either:-

5.2.3.3

(a)

Deterioration is possible at a relatively rapid rate or at a known mean rate which restricts service life or run duration.

(b)

There is little evidence or knowledge of operational effects on which to predict behaviour in service.

Inspection Grade 2 This Grade should be applied when the conditions of service are such that:-

5.2.3.4

(a)

Deterioration has been shown to be at a reasonable and predictable rate, justifying an increased inspection interval.

(b)

Knowledge of actual behaviour in service is reliable enough to justify an increased inspection interval.

Inspection Grade 3 This Grade should be applied when the conditions of service are such that:-

5.2.4

(a)

The item has successfully concluded a period of service in Grade 2.

(b)

Deterioration has been shown to be at a low and predictable rate.

(c)

Knowledge of actual service conditions are sufficiently accurate and reliable to justify an increased interval between inspections.

Criticality Rating Systems A criticality rating system may be used to assist in the determination of inspection grades and frequencies. Criticality rating systems for new plant are based on design criteria and are therefore not suitable on their own for initial grading and scheduling of thorough inspections. Such systems can be used to help identify potential failure mechanisms and estimate failure consequences for specific items of equipment and should not be used to determine generic risk and exposure potentials. Any system used should take full account of the criteria for grade and


PAGE 10

inspection frequency allocation as detailed in sections 5.2.2, 5.2.3 & 5.2.5 of this Recommended Practice. 5.2.5

Determination of Inspection Frequency Each item should normally:(a)

Have a pre-commissioning inspection before entering service for the first time.

(b)

Initially be allocated to Grade 0 and be subject to its first thorough inspection following a comparatively short period of service.

(c)

Subsequently be allocated to Inspection Grade 1, 2 or 3, on the basis of the guidance in 5.2.2 and 5.2.3.

(d)

For Grade 3 items be subject to an inspection review at appropriate intervals to confirm or modify the recommendations of previous inspections.

Table 1 at the end of this Section gives guidance on the maximum intervals which may be allowed to elapse between examinations and reviews for the various Inspection Grades. The recommended maximum intervals given in Table 1 are based on previous BP performance data. Consideration of local operating conditions and results of risk assessment may dictate that the inspection intervals quoted are revised. Reference should be made to 5.2.6 and 5.6 for exemptions to the guidance. 5.2.6

Extensions An extension beyond the date of the next thorough inspection as stated on the last inspection report may be granted. Each case should be considered by the inspection function and if acceptable the management should be formally advised of the extension. In some critical cases it may be appropriate to have formal management approval to extend. This extension shall not cause the maximum inspection interval for the grade to be exceeded by more than twelve months unless (i)

meaningful on-stream examination can be performed which fully satisfies the inspection function

or (ii)

A multidisciplied review including a thorough risk based assessment which supports the extension has been carried out,


PAGE 11

typically as detailed in Appendix C to the full satisfaction of the inspection authority. It is important that detailed records are maintained of any decision to extend. These records should include a clear statement of the authority for such extensions and any calculations or examinations made to justify the extension. 5.3

Class C Equipment Class C equipment should be maintained and inspected as required to ensure it remains fit for continued service. Alternatively it may be treated on a breakdown maintenance basis. However, the decision to allocate an item to Class C should be reviewed on a regular basis to ensure the assumptions made at the time of original grade allocation are still valid.

5.4

Types of Inspection

5.4.1

Initial Thorough Inspection This is for the purpose of establishing:(a)

That the design and construction of the equipment, following a period of service is sound, and that any deficiencies are thoroughly investigated and corrected.

(b)

That standards of fabrication and material quality are fit for their purpose and if not, are corrected.

(c)

That all components essential to the integrity of the equipment are examined, and if appropriate measured and results recorded to permit meaningful safe life predictions.

(d)

That repairs or renewals required are identified and notified to the appropriate authorities and the user.

(e)

That a report, detailing the condition of the equipment is prepared and that the management are made aware of any inspection findings which are likely to prevent the future safe operation of the equipment.

(f)

That the Inspection Grade is reviewed and a date set for the next thorough inspection.


PAGE 12

5.4.2

Subsequent Thorough Inspections These are follow-up inspections and are to ensure that the equipment and all its essential components or fittings are examined and measured and that the results are compared with previous results to enable assessment of corrosion or wastage patterns - or other defects - to be made, predictions made and the remaining safe life to be reliably predicted. As with the initial thorough examination repairs should be identified and if appropriate carried out, reports issued, the Inspection Grade reviewed and a date set for the next inspection.

5.4.3

Sample Inspection Where a group of items of equipment have substantially the same design, geometry and construction and are subject to similar conditions of service such that they will be subject to similar deterioration, the inspection function may accept sample items for thorough inspection. Sampling should be on the following basis:No of items in Group Minimum No of items in sample

2-4

5-8

9 - 12

13 - 40

Over 40

1

2

3

4

10%

Sample inspections may commence at the first examination following commissioning and may continue at subsequent examinations subject always to the proviso that each individual item shall be given a thorough inspection within the maximum period for Grade 3. (See Section 5.5.3). In the event of the findings of a sample inspection being unsatisfactory the Competent Person shall select additional similar items for thorough inspection so that the number of items inspected is at least double that given above. Depending upon the nature of the defect found it may be considered necessary to withdraw all endorsements based on previous sample inspection and reclassify each item individually. If the samples selected for inspection confirm the mechanical integrity of all similar items, those items in the group which have not been thoroughly inspected should have the inspection report endorsed to the effect that;


PAGE 13

"............the item has been passed for service on the results of inspection of Item Number x in this group............". This principle of sampling does not apply to Protective (Safety) Devices or for special application items (e.g. flexible hoses, piping bellows). 5.4.4

Inspection Reviews An inspection review is carried out to assess if there is any evidence to suggest that an Inspection Grade given at the last thorough inspection should be changed. It involves carrying out such on-stream inspection as may be necessary, and examining other relevant data which may be available, e.g. from corrosion probe wastage rates and metal contents of effluent streams. Equipment should be subjected to an inspection review for any of the following:(a)

When an item has been given an Inspection Grade 3 allocation at the intervals stated in Table 1. This is so that a reassessment may be made of the criteria which led to this Grade allocation and whether any changes have occurred since the last thorough inspection which may lead to a possible shortening of the interval before the next thorough inspection.

(b)

When significant changes take place in the conditions of service of any item of equipment, irrespective of its Inspection Grade allocation, which would affect its deterioration.

(c)

When an abnormal incident occurs, which has or could have affected the safety of operation of the item of equipment.

(d)

A special case exists which, in the opinion of the Competent Person and at their discretion, warrants a review irrespective of the Inspection Grade.

When undertaking a review, consideration must be given to any changes in feed quality, feed rates, process upsets, cyclic temperature or pressure excursions, and the number of stops and starts during the period up to the review. Appendix C indicates an approach which may be useful when conducting Inspection Reviews


PAGE 14

5.5

Inspection Grade Transfers

5.5.1

Principles The prime requirement when considering the transfer of an equipment item to a different Inspection Grade is that:-

5.5.2

(a)

An inspection interval should be chosen which takes full account of appropriate design criteria of that item, its service conditions and its condition.

(b)

Decisions on Grade transfers and intervals between (and the extent of) inspection and reviews should be formalised and recorded in the inspection record file so that they are available for enforcing authority scrutiny.

Grade Transfers - Thorough Inspection On the basis of the initial thorough inspection, an item may be transferred to Grade 1 or Grade 2, providing the inspection has indicated that the conditions for this new Grade have been met. On the basis of subsequent thorough inspections, items may be transferred from Grade 1 to 2, and then from Grade 2 to 3, provided the inspection has indicated that the conditions for the new Grade have been met.

5.5.3

Conversely, and on the basis of an inspection, any item in Grade 2 or 3 may be transferred back to Grade 1 or 2 if the results of the inspection indicate that the conditions for the present Grade are not being met. Grade Transfers - Sample Inspections When a sample inspection in accordance with 5.4.3 is performed at the initial thorough inspection, the subsequent interval established between inspections for a sample group should not exceed the maximum for Grade 1. When a sample inspection is again applied at a subsequent thorough inspection, the interval between inspections may be increased to that for Grade 2 or 3 based on the findings of the initial and subsequent inspection. The elapsed time between any two thorough inspections on pressurised equipment should not exceed the maximum intervals given for Grade 3 in Table 1 and the selection of items for sample inspections should be made in compliance with this requirement.


PAGE 15

5.6

Special Cases

5.6.1

Exemptions A request for exemption to the normal grading procedures for equipment may be applied for by the user as detailed in 5.6.2 to 5.6.4 below, provided the following conditions are met:-

5.6.2

5.6.3

(a)

The application is made in writing to the Inspection function giving full details of the reasons why an exemption is required.

(b)

All documentation relating to the request including reasons for acceptance or rejection is retained in the item record file.

(c)

Each approval of such an exemption shall clearly indicate whether the continuation of the exemption is to be subject to review and the maximum interval that shall be allowed to lapse before the initial and subsequent reviews.

Replacement Equipment (a)

Performs a duty similar in all respects to that of an existing item.

(b)

Is substantially the same as the existing item as regards material of construction and design.

Special Design and Construction It is recognised that there may be special cases where, due to the design, construction and/or the conditions of service the principles of this Recommended Practice, are not applicable e.g. certain items in cryogenic service. Deviation from the normal principles are permitted but only when:(a)

A full technical justification, supported and signed jointly by the engineering functions and the inspection function is submitted to the management.

(b)

The management should give written approval to the inspection function to deviate from the usual requirements. Copies of the technical justification must be held in the item inspection record file.


PAGE 16

5.6.4

Mature Design Where process equipment has such design maturity and construction assurance that its operating conditions and rate of deterioration can be predicted with confidence, an Inspection Grade may be allocated based on the service history of similar items. All documentation relating to the above assessment must be recorded and on-stream monitoring carried out to confirm the basis of the assessment.

5.6.5

Deferred Start-up and Intermittent Operation Occasionally, process equipment may not be put back into operation immediately following thorough inspection. As the inspection intervals granted are for a positive expiry date rather than on elapsed operating time, the period out of operation should be regarded as equivalent to a period in operation. Should the outage time exceed 6 months, the inspection engineer should carry out an inspection review and may, at his discretion, take into account all or some of that time which has expired whilst the equipment was not operational. The same approach may be applied to processing plant which is run on an intermittent basis, and an inspection review should be carried out if an item of equipment is out of service for more than 50% of any one 12-month period. When making a decision to revise inspection intervals in such circumstances it must be noted that in both a deferred start-up and intermittent operation deterioration can occur at a rate much faster than normal due to:(a)

External corrosion on insulated equipment.

(b)

Internal corrosion because of water and acidic compounds which may not be damaging at operating temperatures.

(c)

Fouling of equipment because of low flow or stagnant conditions.

(d)

Thermal cycling.


PAGE 17

6.

INSPECTION REPORTS AND RECORDS 6.1

Records The inspection function should ensure that adequate, detailed and auditable records of all items of equipment requiring inspection are maintained. The method by which records are maintained will vary from centre to centre. In all cases, each item of equipment must be uniquely identified and fully described. The records will generally contain the following:(a)

Original basic technical data relating to the item, e.g. design specification, general arrangement drawings, relevant process data.

(b)

Original manufacturing documents, e.g. the inspection authority certificate, material quality documents, pressure vessel code data sheet, rubbings of identification and certification stamps, manufacturer's certification document, alignments, cold and hot clearances, balancing certificates, performance curves, pressure test certificates.

(c)

The construction records issued by the project inspection engineer following delivery to site and prior to being taken into service.

(d)

The inspection classification and registration documents and the Inspection Grade allocated to that item by the inspection engineer.

(e)

All inspection reports issued for that item.

(f)

Documents relating to repairs, modifications or renewals made to that item.

(g)

Calculations made to determine retrial limits, re-assessment of operating conditions or re-rating of the item.

(h)

Documents relating to any abnormal occurrence, including unexpected corrosion, erosion or other defects.

(i)

Specialist reports relating to materials, design, process conditions, etc., which will affect the inspection requirements. See commentary for 4.3.


PAGE 18

6.2

Statutory Documents In many countries there are requirements to maintain certain documentation to satisfy national and local rules and regulations. All such requirements must be strictly observed.

6.3

Reports The Inspection function should issue a detailed inspection report within 28 days of completion of the examination or, for major plant overhauls, within 28 days of the plant being returned to service. As well as describing the 'as found' condition of the item including quantification of any defects found the report should:(a)

Give full details of any repairs or renewals which were carried out and forecast probable repairs or renewals which will be required at the next inspection.

(b)

State areas not accessible for inspection and reasons why.

(c)

Give detailed methods of inspection techniques used including procedures where appropriate.

(d)

State the date the next inspection is due, together with any special facilities, materials or specific components which may be required at that time.

(e)

State if there is any change in the Inspection Grade allocation and inspection intervals and the reasons why.

Copies of the report should be issued as appropriate for each operating centre and a copy placed in the item record file. See commentary for 4.3.


PAGE 19

7.

REVIEW OF INSPECTION FUNCTION 7.1

Introduction In order to ensure that consistent standards of inspection are being applied to BP Group assets and that management can be assured that the inspection functions are being carried out satisfactorily, operating centres should perform and record periodic reviews of their inspection functions to a predetermined schedule. This review programme should take into account the rate of changes in organisation, personnel, procedures, plant, technology and legislation, and the significance of the activity. As a general guide, Internal Reviews should be at least on an annual basis to cover all aspects of the inspection function and may be divided into manageable parts phased over the review period; External Reviews should be at least every three years.

7.2

Internal Review - Self Regulation Internal reviews should be carried out by a team drawn from the operating centre. It is recommended that a locally developed standard format be followed to ensure efficiency. The team should use as their basis the operating centre and inspection function procedures and should report areas where procedures are not being followed. An important element is for the inspection function management to resolve any unsatisfactory findings. Where an operating centre has adopted a philosophy of self regulation there may be no need for a review team. In this situation management should be confident that the inspection function is performing satisfactorily and effectively and is demonstrating self regulation.

7.3

External Review External reviews should be carried out by a team independent of the operating centre inspection function. The team should have specialist inspection knowledge. The basis for the review should be as for an Internal Review but with the important distinction that it should also assess whether the organisation, procedures, systems and practices are in compliance with this Recommended Practice (or other Operating Centre policy) and Statutory Requirements and whether operating centre plant integrity is adequately assured.


PAGE 20

STATUTORY INSPECTION INTERVALS MUST BE FOLLOWED** REFERENCE SECTION

MAXIMUM RECOMMENDED INTERVAL BETWEEN THOROUGH INSPECTIONS (month)

REVIEW PER. FOR Grade 3 ***

RP 32-4

Grade 0

Grade 1

Grade 2

Grade 3

(month)

Steam Equipment excluding Direct Fired Boilers

2

36

48

96

120

84

Direct Fired Boilers

2

24

48

72

-

-

Process pressure vessels

3

36

48

96

144

84

Pressure storage vessels

3

48

72

108

144

96

Gas holders

3

36

48

120

240

108

Non pressure vessels

3

60

72

108

144

96

Lifting Equipment

4

See

BP Group

RP 32-4

Section 4

Storage Tanks

5

See

BP Group

RP 32-4

Section 5

Heat Exchangers

6

36

48

96

144

84

Piping Systems

7

36

48

96

144

84

Fired Heaters

8

24

48

72

-

-

See

Report

ESR.97.ER. 089*

9

See

BP Group

RP 32-5 &

RP 32-6

Stacks and chimneys

10

48

-

72

144

60

Cooling Towers Land Based Steel and Concrete Structures

10

48

-

72

144

60

11

48

-

96

144

84

Jetties

13

48

-

96

144

84

Flexible Hoses

14

See

BP Group

RP 32-4

Section 14

Transmission pipelines

16

See

BP Group

RP 32-4

Section 16

Cryogenic Equipment

18

See

BP Group

RP 32-4

Section 18

Loading Arms

19

See

BP Group

RP 32-4

Section 19

Offshore Installations

20

See

BP Group

RP 32-4

Section 20

PLANT OR EQUIPMENT

Protective

) Relief

devices

) Valves ) Other ) devices

* BP Report; “Recommended practice for the Risk Based Inspection (RBI) of relief valves”. ** See Section 5.1 of this Recommended Practice. *** Review period for equipment with Inspection Grade 3 is consistently defined as twelve months less than inspection interval for grade 2 equipment of the same type. TABLE 1 - EQUIPMENT - RECOMMENDED INSPECTION INTERVALS


PAGE 21

APPENDIX A DEFINITIONS AND ABBREVIATIONS Definitions Standardised definitions may be found in the BP Group RPSEs Introductory Volume. class:

a BP classification of equipment for inspection purposes

competent person:

a person (who may be a body of persons or an individual person) having such practical and theoretical knowledge and actual experience of the type of equipment to be examined as will enable him to detect defects or weaknesses which it is the purpose of the examination to discover and to assess their importance in relation to strength and function of the equipment. The person must be qualified and trained to a standard sufficient to meet any applicable statutory regulations.

enforcing authority:

the authority which enforces the provisions of any legal requirements relating to inspection of plant and equipment.

engineering function:

a generic term covering both the design and maintenance engineering function.

equipment:

all items or systems of production, processing, storage, utilities and other installations.

inspection:

the examination or examination and physical test or checking of functional operation.

inspection function:

that person or body appointed by the management to be responsible for the examination and certification of equipment utilised within the operating centre. The inspection function may be an external body specialising in the inspection of equipment.

inspection engineer/inspector:

an engineer appointed by the management to be responsible to the inspection function for the inspection of equipment within the operating centre.

management:

the person or persons legally responsible for an operating centre owned or operated by BP.

operating centre:

the facility within the control and jurisdiction of the management.


PAGE 22

surveyor:

an inspector engineer working on behalf of the enforcing authority.

thorough inspection:

critical scrutiny in or out of service as appropriate. The methods and extent of this scrutiny must be sufficient to satisfy the inspection function that the equipment is fit for continued service and will:(a)

detect defects or weaknesses in relation to the strength and functions of the equipment being examined and to ascertain its condition.

(b)

measure the rate and identify the type and cause of wear and deterioration.

(c)

collect sufficient data on which to predict future service life for safe, efficient, continuous operation.

(d)

establish the period for which the equipment may be used prior to the next thorough examination.


PAGE 23

APPENDIX B LIST OF REFERENCED DOCUMENTS A reference invokes the latest published issue or amendment unless stated otherwise. Referenced standards may be replaced by equivalent standards that are internationally or otherwise recognised provided that it can be shown to the satisfaction of the purchaser's professional engineer that they meet or exceed the requirements of the referenced standards.

European Standards EN 45004

General criteria for the operation of various types of bodies performing inspection

BP Group Documents BP Group RP 32-1

Inspection and Testing of New Equipment in Manufacture (replaces BP CP 51)

BP Group RP 32-2

Site Inspection, Testing and Pre-commissioning of New Plant. (replaces BP CP 20)

BP Group RP 32-4

Inspection and Testing of In-Service Civil and Mechanical Plant - Technical Guidance (replaces the relevant parts of BP CP 52)

BP Group RP 32-5

Inspection and Testing of In-Service Electrical Plant (replaces the relevant parts of BP CP 52)

BP Group RP 32-6

Inspection and Testing of In-Service Instrumentation (replaces the relevant parts of BP CP 52)

*ESR.97. ER.089

BP Report; “Recommended Practice for the Risk Based Inspection (RBI) of relief valves

*BP Report available from the custodian of this Recommended Practice


PAGE 24

APPENDIX C ENDORSEMENT REVIEW PROCEDURE C.1

Introduction This Appendix specifies a systematic approach for reviewing Endorsement Periods of Static Equipment, it is auditable, reproducible and takes account of the consequences of failure and links with initial grades and grade reviews as recommended in RP 32 series. It is a balanced and robust system designed to get to the correct and most appropriate grade and inspection interval (which may be reduced), it removes some of the subjectivity which formerly resided with the Inspection Engineer, this process now being a team approach. The process is conducted in an impartial way, the output of the process being appropriate to the study, it is not just a tool to generate increased inspection periods. The process also reflects changing technology (e.g. Non Invasive Inspection) and legislation (e.g. emissions to environment, disposal of contaminated materials, confined space entry) which must be taken into consideration and attempts to meet these other requirements and not just the requirements of Pressure Systems Regulations. The process draws from existing reliability, safety and failure analysis models but is a separate stand alone system that is available to perform the specific task of Endorsement Review. To conduct the study, a team of suitably experienced personnel are assigned under the leadership of a chairman. These personnel will normally be discipline engineers with a detailed knowledge of the process plant and equipment under review. The quality of the study will be dependant both on the constitution of the team, and the accuracy of the base information employed. Therefore it is important that the significant input required from all team members during the data collection stage is given; to ensure that information is as accurate as possible and that all the data required is collected


PAGE 25

C.2

Methodology The method used shall be as described below. The study is carried out in a very similar manner to that of a HAZOP. The programme is comprised of four basic stages, to be completed sequentially. These four stages are shown in the flowchart below:-

Set up Study

Preparation for Study

Definition of Outputs Selection of Team Definition of Schedule Preparation of Forms Data Collection Criticality Analysis Data Collation Process Overview Operation Overview Inspection Overview Maintenance Overview Discussion - Guidewords

Study

Action and Follow up

Draft Report Action Findings Review Findings Final Report

For each stage, the method used shall be described in the relevant section of this RP. For each stage a detailed description of the activity will be given and the roles and responsibilities identified. An example of a completed study is given in Section C.11


PAGE 26

C.3

Set up Study Set up Study

Definition of Outputs Selection of Team Definition of Schedule

The ‘Set up Study’ stage should identify clearly the outcome of the review, the team that will undertake the review and the timescale in which it is to be completed. C.3.1 Definition of Possible Outcomes Responsibility for completion of this stage lies with the Job Engineer and Chairman. The definition of clearly expected outcomes must be carried out and will be appropriate to the extent of the review, e.g. a whole system or selected single plant items. System definition must include Pipework and Safety Related Devices therein and how they are to be treated. This also applies any electrical equipment such as motors and switchgear and mechanical machinery too. Typical review topics are: Maintenance / Inspection practices Operational control Feed quality changes Corrosion control systems Operational limiting factors The definition of outputs will be circulated to each member of the team taking part in the study. The definition of outputs must be concise and define exactly the extent of the review, identifying each distinct fluid stream (i.e. COD overheads or cooling water), and by TAG number each piece of equipment to be included in the study. On larger or more complex plant items, the exact area or stream should also be identified (i.e. a column top or exchanger shellside). For the purposes of the study, it may be beneficial to group duplicate plant items on the same duty (i.e. heat exchangers in parallel) for discussion at the one time. The selection and identification of such groups will be at the discretion of the Chairman and Job Engineer.


PAGE 27

Possible Outputs are:-

C.3.2

(a)

Written scheme of Examination may have to be amended

(b)

The Endorsement Period may be changed

(c)

The Grading may be altered

(d)

Changes to Maintenance Procedures

(e)

Changes to operational Procedures

(f)

On Stream Inspection may be necessary

(g)

Special Studies may be required

(h)

Plant Modifications may be required

Selection of Team Responsibility for completion of this stage lies with the Job Engineer and Chairman. The team should consist of the minimum number of persons necessary for the required range of expertise to be available for the study. Provided all the necessary experience and disciplines are covered, the team will normally consist of four core members as follows; Study Leader Inspection Engineer Maintenance Engineer Process Engineer Operations Engineer Chairman must satisfy themselves that the nominated personnel are suitably qualified and experienced with the equipment under consideration. In addition, other personnel may be co-opted to advise on special problems identified during the study, or to support the existing team members. These additional personnel may be from within or without the company.


PAGE 28

Examples of other disciplines that may be required are; Electrical / Instrumentation Engineer Corrosion Engineer QRA Assessor Safety Engineer Design Engineer C.3.3

Definition of Schedule Responsibility for completion of this stage lies with the Job Engineer and Chairman. A plan and schedule that has asset support should be generated and adhered to.

C.4

Preparation for Study Preparation of Forms

Preparation for Study

Data Collection Criticality Analysis Data Collation

C.4.1

Preparation of Forms (NOTE: This is a site specific requirement, other sites may be able to satisfy this requirement electronically from their own computer systems.) Responsibility for completion of this stage lies with the Job Engineer. To simplify the matter of Data collection and ensure that the required information is gathered effectively, three forms have been generated; Plant Item Information Form

Technical information for each process item.

Response Form

Responses by discipline engineers to given prompts.

Fluid Definition Form

Specific process information for each fluid stream

The forms have been generated in a similar format. Each is subdivided into a number of sections to be filled out by the relevant discipline engineer. Each section has a grey header identifying the title of that


PAGE 29

section on the left and the engineer responsible for completion of that section on the right. Explanations for completion of the PIIF, RF and FDF are given in sections C7, C8 and C9 respectively. C.4.1.1

Plant Item Information Form (PIIF) For each item, or defined group of items, a PIIF should be generated. The Job Engineer should complete the ‘Common Details’ section before circulation to the Process / Operations and Inspection Engineers for completion.

C.4.1.2

Response Form (RF) For each PIIF a RF should also be generated. The Job Engineer should complete the ‘Common Details’ section before circulation to the core team for completion.

C.4.1.3

Fluid Definition Form (FDF) For each distinct fluid stream, a FDF should be generated. The Job Engineer should complete the ‘Common Details’ section before circulation to the Process / Operations engineer for completion. Example:-

For the two heat exchangers, E101 and E102 illustrated above, assuming they are on the same duty and can thus be considered as a ‘group’ of two items, six forms would require to be generated; Two FDFs, one for ‘Stream 1’ and one for ‘Stream 2’. Two PIIFs, one for E101 and E102 shellside and one for E101 and E102 tubeside. Two RFs, one for each PIIF.


PAGE 30

In addition to the information from the team members, a simplified RFX and full size set of EFD’s will be required, 1 set per 3 attendees. The extents of the study as given in the definition of objectives, should be clearly marked. Copies of the FDF, PIIF and RF forms are given in section C.10. C.4.2

Data Collection Responsibility for completion of this stage lies with the team members. The forms generated by the Job Engineer are circulated to the team members along with the definition of objectives, the team selected and the schedule. All forms should be returned to the Job Engineer by the completion of the Data Collection stage as indicated on the schedule. Each of the team members are responsible for completion of the PIIFs, RFs and FDFs as detailed in Sections C7, C8 and C9 respectively.

C.4.3

Criticality Analysis Responsibility for completion of this stage lies with the Job Engineer. To compliment the study, a risk based analysis tool may be employed. This analysis should identify both a probability and consequence of failure, which can then be combined to give an overall criticality rating. All the information required to complete the risk based analysis should be contained on the completed PIIF for each item, or defined group of items. The results of the analysis should be entered into the relevant PIIF as detailed in section C.8.2. In addition the results it is suggested that the results are also prepared graphically for presentation at the study.

C.4.4

Data Collation (NOTE: the forms are site specific, other sites may satisfy this requirement electronically with their own computer systems) Responsibility for completion of this stage lies with the Job Engineer. The completed RF’s and PIIF’s from the team members should be collated onto a single RF and PIIF for each item, or defined group of items. To facilitate Data Collation, it is suggested that the forms are circulated digitally, either across a network or by diskette.


PAGE 31

To allow the chairman to familiarise himself will the plant items under review, the collated RF’s and PIIF’s should be copied to the chairman at least one week prior to the study. C.4.5

Site Visit Responsibility for completion of this stage lies with the team members. At the discretion of the chairman, all members of the team not sufficiently familiar with the items to be

C.5

Study Process Overview

Study

Operation Overview Inspection Overview Maintenance Overview Discussion - Guidewords

The ‘Study’ stage should include an overview by each of the discipline engineers, followed by a structured discussion based on both defined guidewords and the data collated during the previous stage. C.5.1

Process Overview Responsibility for completion of this stage lies with the Process Engineer. With reference to the system FDX and EFD’s, the Process Engineer will give a brief outline of the system process as a whole, this should include the following points; Process history Specific process requirements for plant items within scope Specific limiting factors for plant items within scope Possible future process issues Any additional comments and information should be recorded on the relevant RF by the Job Engineer.

C.5.2

Operation Overview Responsibility for completion of this stage lies with the Operations Engineer. With reference to the system FDX and EFD’s, the Operations Engineer will give a brief outline of the operation issues of the system as a whole, this should include the following points; Operation history Routine operation Specific operation requirements for plant items within scope


PAGE 32

Specific limiting factors for plant items within scope Factors that can result in abnormal and upset conditions Possible future operation issues Any additional comments and information should be recorded on the relevant RF by the Job Engineer. C.5.3

Inspection Overview Responsibility for completion of this stage lies with the Inspection Engineer. With reference to the system FDX and EFD’s, the Inspection Engineer will give a brief outline of the inspection issues of the system as a whole, this should include the following points:Inspection history Routine inspection Specific inspection requirements for plant items within scope Specific limiting factors for plant items within scope Possible future inspection issues Any additional comments and information should be recorded on the relevant RF by the Job Engineer.

C.5.4

Maintenance Overview Responsibility for completion of this stage lies with the Maintenance Engineer. With reference to the system FDX and EFD’s, the Maintenance Engineer will give a brief outline of the maintenance of the system as a whole, this should include the following points; Maintenance history Routine maintenance Specific maintenance requirements for plant items within scope Specific limiting factors for plant items within scope Possible future maintenance issues Any additional comments and information should be recorded on the relevant RF by the Job Engineer.

C.5.5

Discussion - Guidewords Responsibility for completion of this stage lies with the Chairman and Job Engineer. Given that each member of the team will now have a basic understanding of the system, it is now possible to isolate and discuss discrete sections of the system.


PAGE 33

Working from the list of equipment items identified for study. Each plant item or group of plant items are identified on the EFD/P&ID’s. The chairman will work sequentially through the RF, using the factors as a basis for discussion. The RF is intended to ensure that certain factors are not omitted, but is not exhaustive, additional factors should also be considered where applicable to a plant item. Any additional comments and information should be recorded on the relevant RF by the Job Engineer. At the discretion of the Job Engineer and Chairman, any findings and recommendations made by the study should be noted on the Finding / Recommendation / Response Form (FRRF). Copies of the FRRF form are given in Section C.11. C.5.6

Typical guidewords and statements for the chairman to consider Are there any outstanding repairs, HAZOP, PHSER or other actions outstanding to the system ? Are there any modifications planned ? Any Engineering standards that have to be considered and applied retrospectively? Any parts of the Operational system that is not included in the terms of reference that should be considered, as it may have an impact on the safety of the system being reviewed? Materials of Construction Fluid Composition Flow Pressure Temperature Level Chemical Reaction Power Corrosion Emissions Start-up Shutdown Normal Conditions Upset Conditions Maintenance Other The above guide phrases/words are in matrix form in Section C.10.

C.5.7

The team agree response and any subsequent actions arising.


PAGE 34

C.6

Action and Follow Up Draft Report

Action and Follow up

Action Findings Review Findings Final Report

The ‘Action and Follow Up’ stage, should close out the review. A draft report should be issued and findings from the study actioned. On completion a final report is compiled for the client. C.6.1

Draft Report Responsibility for completion of this stage lies with the Chairman and Job Engineer. A draft report should be compiled, containing; Executive Summary Introduction Definition of Outcomes Selection of Team Definition of Schedule Findings and Recommendations Index of Findings All relevant forms (FRRF, PIIF, RF and FDF) should be appended along with the review schedule. An example of a completed study is given in Section C.12.

C.6.2

Action Findings Responsibility for completion of this stage lies with the Client and Job Engineer. Actions arising should be agreed with the client and entered into an action tracking system and pursued to formal close out. Copies of the draft report should be passed to the client, review team and any actionees identified on the Finding/Recommendation/Response Form (FRRF). Responses should be returned to the Job Engineer by the date set in the schedule.


PAGE 35

C.6.3

Review Findings The review team shall meet to review the responses to the findings raised. Any comments should be noted on the relevant FRRF.

C.6.4

Final Report Once all the findings and responses have been accepted by the review team, a final report should be compiled in a similar structure to that of the draft report. This final report should be signed by the Job Engineer, Chairman and relevant Endorsing Authority, as detailed below:C.6.4.1

C.7

Where the review recommends modifications to the written scheme of examination, or endorsement frequency, or grading as per the anticipated outcomes the Inspection Group leader should be the Endorsement Authority.

Plant Item Information Form Responsibility for completion of this form lies with the Job Engineer, Process / Operations and Inspection Engineer. All forms have been generated in a similar format. Each is subdivided into a number of sections to be filled out by the relevant discipline engineer. Each section has a grey header identifying the section title left and the engineer responsible for completion of that section on the right. C.7.1

Common Details - Job Engineer A description of the item or defined group of items should be noted and the TAG and WIN numbers for each item entered.

C.7.2

Normal Operation - Process / Operations Engineer Inlet and outlet pressure and temperatures should be entered for the plant item under normal operation.

C.7.3

Upset Conditions - Process / Operations Engineer Inlet and outlet pressure and temperatures should be entered for the plant item during upset conditions. ‘Worst case’ upset conditions should be considered, during abnormal operation, commissioning or decommissioning.

C.7.4

API RBI Level 1 Details - Process / Operations Engineer This information is required to perform the API risk analysis. The majority of questions require an answer from a pick list.


PAGE 36

Representative Fluid - Defined as follows; Light HC Process stream mainly C1-C5. Medium HC Process stream mainly C6-C16 Heavy HC Process stream mainly C16-C25+ Capacity - Defined as follows; Low Medium High

Release will result in total deinventory of plant item. Release will result in total deinventory of plant item plus 1-10 others. Result will result in total deinventory of plant item plus 10+ others.

Business Interruption - Defined as follows; No SD No shutdown, little or no effect on throughput. Short SD 1-2 day shutdown, or reduced throughput. Extended SD 2+ day shutdown, or severely reduced throughput. Phase In the API model, this can only be selected as liquid or gas. If the fluid exists in a two-phase state, as a worst case scenario, gas should be entered. Percentage Toxicity The toxicity of the process stream expressed as a percentage. Sold out Market Expressed as a yes / no dependant on whether the market is ‘sold out’. C.7.5

TISCHUK Details - Process / Operations Engineer This information is required to perform the TISCHUK risk analysis. As with the API the majority of questions require an answer from a pick list. Contents A description of the process stream should be entered, this should be the same as the description of the process stream given on the relevant FDF.


PAGE 37

Capacity - As with the API, this is defined as follows:0.227 m3 2.270 m3 22.70 m3

Release will result in total deinventory of plant item. Release will result in total deinventory of plant item plus 1-10 others. Result will result in total deinventory of plant item plus 10+ others.

Location Within Plant This provides a rough assessment of the hazard to personnel and to other equipment. Defined as follows; 3 2 1

Inaccessible or infrequently visited, such as a sump. General plant area. Inside an enclosure such as a pump / compressor house.

Phase In the TISCHUK model, this can be selected as liquid, two-phase or gas. Financial Consequences This provides an estimate of the cost of failure of a line. Defined as follows:3 2 1

Negligible total cost, less than 24 hours lost production or equivalent. Moderate total cost, 1-7 days lost production or equivalent. High total cost, 7+ days lost production or equivalent.

Standby Availability This provides an assessment of the effect of a failure on the plant operation. Defined as follows; 3 2 1 C.7.6

Allow the use of bypass or alternate production route. Cause operating problems or reduce throughput. Jeopardise plant operation or cause shutdown.

API RBI Level 1 Details - Inspection Engineer This information is required to perform the API risk analysis. The majority of questions require an answer from a pick list. Material of Construction


PAGE 38

The material of construction, must be selected from the following pick list; Carbon Steel Carbon 1/2 Mo (Annealed) Carbon 1/2 Mo (Normalised) Cr 1/2 Mo (PWHT'd) 1 1/4 Cr 1/2 Mo (PWHT'd) 2 1/4 Cr 1/2 Mo (PWHT'd) Austenitic Stainless Steel 300 Series Stainless 321 Series Stainless 347 Series Stainless H Grade Stainless L Grade Stainless Alloys 600 Alloys 800 Alloys 625 Alloys 20 Years since last inspection This should account for the year since the last inspection to the date at which the form was filled out. It is only necessary for this to be accurate to the nearest year. Deterioration Found Expressed as a yes / no for each of the six mechanisms identified, dependant on any deterioration found. C.7.7

TISCHUK - Static Equipment Details This information is required to perform the TISCHUK risk analysis. These questions do not require an answer from a pick list and can be entered as free text. To determine nominal wall for heat exchanger tubebundles, convert the BWG or SWG into wall thickness in mm.

C.8

Response Form Responsibility for completion of this form lies with the core team members; Job Engineer, OCA Assessor Process / Operations, Inspection Engineer, Corrosion Engineer, Maintenance Engineer and Electrical / Instrument Engineer.


PAGE 39

All forms have been generated in a similar format. Each is subdivided into a number of sections to be filled out by the relevant discipline engineer. Each section has a grey header identifying the section title left and the engineer responsible for completion of that section on the right. C.8.1

Common Details - Job Engineer A description of the item or defined group of items should be noted and the TAG and WIN numbers for each item entered.

C.8.2

Criticality Analysis - OCA Assessor Probability, Consequence and overall Criticality ratings should be entered for the plant item or group of plant items and an indication of the driving factor given.

C.8.3

Operation / Process Factors - Process / Operations Engineer The factors identified should be considered for the plant item or group of plant items. If any comments are made, the box alongside the relevant factor should be blacked out and comments made alongside. Where a factor has been considered and no comment has been made, the box should be shaded grey.

C.8.4

Inspection Factors - Inspection Engineer As for C.8.3

C.8.5

Corrosion Factors - Corrosion Engineer As for C.8.3

C.8.6

Maintenance Factors - Maintenance Engineer As for C 8.3

C.8.7

Electrical/Instrumentation Factors - Electrical/Instrumentation Engineer As for C.8.3

C.9

Fluid Definition Form Responsibility for completion of this form lies with the Job Engineer and Process / Operations Engineer. The forms have been generated in a similar format. Each is subdivided into a number of sections to be filled out by the relevant discipline engineer. Each section has a grey


PAGE 40

header identifying the title of that section on the left and the engineer responsible for completion of that section on the right. C.9.1

Common Details - Job Engineer A description of distinct process stream should be entered. For example, ‘Water’ or ‘IC4 Recycle’.

C.9.2

Fluid Content - Process / Operations Engineer The fluid content in terms of Water, H2S, CO2, Elemental Hydrogen, Sulphur, Chloride and Oxygen and Vapour Liquid Ratio should be expressed in terms of the units given on the right side of the section; where known.

C.9.3

Fluid Makeup - Process / Operations Engineer In order to identify the base fluids which make up the process stream from the picklist given, the box to the right of each of the relevant fluids should be blacked out.


PAGE 41

Guide phrases/words in matrix format

ITEM

REP AIRS?

HAZOP? PHS ER?

PMP?

MATL of CONSTRN

FLUID? COMPO SITION?

FLOW ?

PRE SS?

TEMP ?

LEV EL?

REA CTION?

C.10

Page 1 of 2


PAGE 42

OTHER? MAINTENANCE? UPSET CONDS? NORMAL CONDS? SHUT DOWN? START UP? EMISSIONS? CORROSION? POWER? ITEM

Page 2 of 2


PAGE 43

C.11

Blank examples of PIIF, FDF and RF forms

PLANT ITEM INFORMATION FORM Common Details Tag No:

FORM PIIF Job Engineer Win No:

Description: Normal Operation Inlet Pressure (Bar): Inlet Temperature (Deg C):

Process / Operations Engineer Outlet Pressure (Bar): Outlet Temperature (Deg C):

Upset Conditions Inlet Pressure (Bar): Inlet Temperature (Deg C):

Outlet Pressure (Bar): Outlet Temperature (Deg C):

API RBI Level 1 Details Representative Fluid Capacity: Business Interruption:

Phase (Liquid / Gas): % Toxic: Sold out Market (Y/N):

TISCHUK Details Contents: Capacity (m3): Location Within Plant (1-3):

Phase (Liquid / T-Phase / Gas): Financial Consequences (1-3): Standby Availability (1-3):

API RBI Level 1 Details Material of Construction: Internal Corrosion Found (Y/N) SCC Found (Y/N) Fatigue Found (Y/N):

Inspection Engineer Years since last inspection: CUI Found (Y/N): Creep Found (Y/N): Embrittlement Found (Y/N)

TISCHUK Details Material of Construction: Design Pressure (Bar): Test Pressure (Bar): Heat Treatment: Tracing (Steam / Electric): Nominal Wall (mm): Shell OD (mm) Internal furnitures / fittings:

Material Specification: Design Temperature (Deg C): Design Code: Lining: Lagged (Y/N): Corrosion Allowance (mm): Inspection Grade: Current Endorsement (months):


PAGE 44

FLUID DEFINITION FORM

FORM FDF 1

Fluid: Common Details Water Content: H2S Content: CO2 Content: Hydrogen Content: Sulphur Content: Chloride Content: Oxygen Content: Vapour Liquid Ratio

Y/N PPM % % % PPM PPM Cu ft/Barrel

Common Details /ACETALDEHYDE/ /ACETIC ACID/ /ACETIC ANHYDRIDE/ /ACETONE/ /ACETONITRILE/ /ACETYL CHLORIDE/ /ACETYLENE/ /ACROLEIN/ /ACRYLIC ACID/ /ACRYLONITRILE/ /AERATED ACETIC ACID/ /AERATED HYDROCHLORIC ACID/ /AERATED HYDROFLUORIC ACID/ /AERATED PHOSPHORIC ACID/ /AERATED SULFURIC ACID/ /AIR/ /ALLYLAMINE/ /AMMONIUM HYDROXIDE/ /AMMONIUM BISULPHITE/ /ANNHYDROUS AMMONIA/ /ANNHYDROUS CARBON DIOXIDE/ /ANNHYDROUS HYDROGEN CHLORIDE/ /ANNHYDROUS HYDROGEN FLUORIDE/ /ANNHYDROUS HYDROGEN SULFIDE/ /ANTIFOAM/ /ASPHALT/

/DIETHYL ETHER/ /DIETHYL KETONE/ /DIETHYLAMINE/ /DIETHYLENE GLYCOL/ /DIETHYLENETRIAMINE/ /RICH DIISOPROPANOLAMINE/ /DIISOPROPANOLAMINE / /DIISOPROPYL ETHER/ /DIISOPROPYLAMINE/ /DIMETHYLDISULFIDE/ /DIMETHYLAMINE/ /DIPHENYLAMINE/

/METHYLPROPYL KETONE/ /MONOETHANOLAMINE/ /RICH MONOETHANOLAMINE/ /MONOETHYLENE GLYCOL/ /MORPHOLINE/ /NAPHTHA/ /NAPTHALENE/ /NATURAL GAS/ /NGL/ /NITRIC ACID/ /NITROGEN/ /NONANE/

/DISULFIDE OIL/

/OCTANE/

/ETHANE/

/ETHYL MERCAPTAN/ /ETHYL PROPIONATE/ /ETHYLAMINE/ /ETHYLBENZENE/

/OIL BASED DRILLING MUD/ /OXYGEN/ /PARAFORMALDEHYDE/ /PARATOLUENE SULFONIC ACID/ /PENTANE/ /PHENOL/ /PHOSPHORIC ACID/ /PHTHALIC ACID/

/ETHYLENE GLYCOL/

/PHTHALIC ANHYDRIDE/

/ETHYLENE OXIDE/

/POLYETHYLBENZENE/

/ETHYLENE/

/POLYETHYLENE/

/ETHYLENEDIAMINE/ /FLUORINE/

/POLYPROPYLENE/ /POLYSTYRENE/

/ETHANOL/ /ETHYL ACETATE/ /ETHYL CHLORIDE/


PAGE 45

FLUID DEFINITION FORM

FORM FDF 2

/BENZENE/ /BENZOIC ACID/ /BENZYL ACETATE/ /BENZYL ALCOHOL/ /BENZYL CHLORIDE/ /BROMINE/ /BUTADIENE/ /BUTANE/ /BUTANOL/ /BUTENE/ /BUTYL ACETATE/ /BUTYLENE/ /BUTYRIC ACID/ /C1/ /C10/ /C12/ /C15/ /C2/ /C20/ /C3/ /C4/ /C5/ /C6/ /C7/ /C8/

/FORMALDEHYDE/ /FORMIC ACID/ /FREON/ /FUEL OIL/ /FURFURAL/ /GASOIL/ /GASOLINE/ /GLUTERALDEHYDE/ /HALON/ /HEAT TRANSFER OIL/ /HEAVY FUEL OIL/ /HEPTANE/ /HEXANE/ /HEXANOL/ /HYDRAULIC FLUID/ /HYDRAULIC OIL/ /HYDRAZINE/ /HYDROBROMIC ACID/ /HYDROCHLORIC ACID/ /HYDROFLUORIC ACID/ /HYDROGEN CYANIDE/ /HYDROGEN PEROXIDE/ /HYDROGEN SULFIDE/ /HYDROGEN/ /HYDROQUINONE/

/C9/ /CALCIUM CHLORIDE/ /CARBON DIOXIDE/ /CARBON DISULFIDE/ /CARBON MONOXIDE/ /CARBON TETRACHLORIDE/ /CAUSTIC/ /CHLORINE/ /CITRIC ACID/ /CORROSION INHIBITOR/ /CRUDE OIL/ /CUMENE/ /CYCLOHEXANE/

/ISOBUTANE/ /ISOBUTANOL/ /ISOBUTYL ACETATE/ /ISOHEXANE/ /ISOOCTANE/ /ISOPENTANE/ /ISOPHORONE/ /ISOPROPANOL/ /ISOPROPANOLAMINE/ /ISOPROPYL ACETATE/ /ISOPROPYL ETHER/ /KEROSENE/ /LIQUIFIED PETROLEUM GAS/ /LONG RESIDUE/ /LPG/ /LUBE OIL/ /METHANE/ /METHANOL/ /METHYL ACETATE/ /METHYL PROPIONATE/ /METHYLBUTYL KETONE/ /METHYLETHYL KETONE/

/CYCLOPENTANE/ /DEAERATED SEAWATER/ /DECANE/ /DEMULSIFIER/ /DETERGENT/ /DIBUTYLAMINE/ /DIESEL/ /RICH DIETHANOLAMINE/ /DIETHANOLAMINE/

/POTASSIUM HYDROXIDE/ /PROPANE/ /PROPANOL/ /PROPIONALDEHYDE/ /PROPIONIC ACID /PROPYL ACETATE/ /PROPYLENE GLYCOL/ /PROPYLENE OXIDE/ /PROPYLENE/ /SALT/ /SCALE INHIBITOR/ /SEAWATER/ /SHORT RESIDUE/ /SODIUM BICARBONATE/ /SODIUM HYPOCHLORITE/ /STEAM/ /STYRENE/ /SULFOLANE/ /SULFUR DIOXIDE/ /SULFUR TRIOXIDE/ /SULFUR/ /SULFURIC ACID/ /SULFUROUS ACID/ /TETRAETHYL LEAD/ /TETRAETHYLENE GLYCOL/ /TOLUENE/ /TOPANOL/ /TRIBUTYLAMINE/ /TRICHLOROETHANE/ /TRICHLOROETHYLENE/ /TRIETHANOLAMINE/ /TRIETHYLAMINE/ /TRIETHYLENE GLYCOL/ /TRIISOPROPANOLAMINE/ /TRIMETHYLAMINE/ /VINYL ACETATE/ /VINYL CHLORIDE/ /WATER BASED DRILLING MUD/ /WATER/ /XYLENE/ /METHYL IODIDE/ /ETHYLIDENE DIACETATE/ /RHODIUM ACETATE/ /LITHIUM ACETATE/ /IMIDAZOLE/ /A5 POLYMER/


PAGE 46

RESPONSE FORM

FORM RF (1)

Common Details Tag No:

Job Engineer Win No:

Description: Criticality Analysis Probability rating Consequence rating Criticality rating

OCA Assessor

Operations / Process Factors Operation history Impact on unit operation Impact on other units Impact on personnel Potential for fouling Operational window Fluid quality Upset conditions Isolation / Gas freeing Other

Process/Operations Engineer

Inspection Factors Inspection history General / local wastage Isolated / multiple pitting Surface / embedded cracks Microstructural change Delamination Ultrasonic Radiography DPI MPI Additional NDT techniques Design suitable for NDT Endorsement frequency Weldability Welding Procedure Post Weld Heat Treated Repair considerations Other

Inspection Engineer


PAGE 47

RESPONSE FORM

FORM RF (2)

Corrosion Factors Internal Corrosion CUI SCC Creep Fatigue Embrittlement PCMS Data Corrosion Prevention Material Considerations Other

Corrosion Engineer

Maintenance Factors Accessibility Sparing / Availability Item reliability Routine maintenance Other

Maintenance Engineer

Electrical / Instrumentation Factors Trip Testing CV's Other

Electrical/Instrumentation Engineer


PAGE 48

C.12

Example Review

FINDING / RECOMMENDATION / RESPONSE FORM

FORM FRRF

Common Details

Job Engineer

Tag No:

Win No:

Description: Finding Finding Reference:

Job Engineer

Recommendation

Job Engineer

Raised by :

Team

Date :

Response

By :

Date :

Review Team Comment

: By

: Date


PAGE 49

RP32 3InServiceInspection Manag.

Recommend Documents