RBI Implementation Project –Data Acquisition, Circuitization, RBI Analysis & Inspection Planning for QatarEnergy Refinery, Mesaieed, Qatar
Scope
The Project Scope of work included Risk-Based Inspection of the static equipment and piping for the following Units of Chemical Plant Linear Alkyl Benzene (LAB):
- Kerosene Prefractionation Unit
- Molex Process Unit
- Pacol Process Unit
- Pep Process Unit
- Detal Process Unit
- Hot Oil System
- Sulfolane Process Unit
- Off-Site Units
Process
The methodology of this project involves the utilization of the APMS Mechanical Integrity (MI) module to implement RBI across Chemical Plant Linear Alkyl Benzene (LAB) operations. A comprehensive approach was set forth to ensure the essential components of the project scope, including:
Outcome
Velosi’s team of expert individuals successfully conducted a Risk-Based Inspection (RBI) study for a Chemical Plant utilizing the APMS Mechanical Integrity (MI) module as per COMPANY requirements.
The Project, completed not only met but exceeded client expectations. Despite facing numerous challenges throughout the process, our dedicated team demonstrated exceptional resilience and adaptability, ensuring that all objectives were achieved. The project was concluded by submitting high-quality deliverables that aligned with the client’s vision and requirements. This success reflects our commitment to excellence and our ability to navigate complexities while maintaining a focus on client satisfaction and asset reliability.
Deliverables
Team Velosi developed and submitted the following deliverables:
- Validate /Update Asset Register.
- Development of Corrosion Loops and Piping Circuits (Marked up PFD and P&ID)
- Develop Corrosion Loop Descriptions (Physical Descriptions, Process Descriptions, Damage Mechanism Descriptions, IOW, etc.)
- Create Corrosion loops in APM.
- Corrosion loop-wise IOW identified list with lower, upper limits, criticality of IOWs to monitor, and their frequency of monitoring and alerts.
- Development data loaders for RBI, IM, and TM modules
- Validate and complete all data in all mechanical integrity modules (TML, IM, and RBI)
- Development of Inventory Group – Equipment Boundaries
- RBI Assessment (POF & COF) based on APM -Semi-quantitative and Quantitative approach.
- Develop an inspection plan at the component level (Scope, Extend, Technique, etc.) m. Detailed Inspection plan for SPOF systems
- Identified Dead leg and injection points register and marked up ISOs and verified at the site for physical availability.
- Inspection Isometrics with CML locations identified.
- Using current inspection history and Thickness data (Stored in APM and external sources) to calculate the required confidence and Corrosion Rate to be used in RBI.
- Create an inspection task based on the RBI recommendation in APM after managing the RBI recommendation on the asset level.
- Prepare a summary integrity report include all used assumptions and RBI results based on the unit level.
- Development of data library.
- Piping: Create Piping Groups in SAP, Link Piping Tags to groups, RBI analysis on group level, and generate inspection tasks and reports. TML data mapped to these new circuit levels.