SABIC Petrokemya – RBI Studies (Piping Re-Circuitization Project Phase-II)
Scope
The Project Scope of work includes Risk Based Inspection of the static equipment and piping for the following Units of PetroKemya OLEFINS-1/2/3 Plants:
- Corrosion Loop Drawings & Assigning Damage Mechanisms
- Corrosion Loop Description
- Development of Integrity Operating Windows
- Inventory Group Drawings
- Piping Circuit Drawings & Piping Circuit Master list
- SAP Upload Template to create New Assets
- RBI Meridium Templates for Risk Assessment
- RBI Meridium Template for Corrosion Loops
- RBI Meridium Template for TML Structure creation
- Inspection Strategies creation and Management in Meridium
- Link RBI Component with Corrosion loops in Meridium
- CML marked Isometric Drawings
- Redundant Old Piping Circuits and Old Inspection Tasks in SAP and Meridium
Process
The methodology of this project involves a comprehensive approach set forth to ensure essential components to project scope as:
- Velosi has used line list, Engineering Data, Piping Material / Class Document to develop Asset Register for all Piping.
- Material Selection Diagrams have been developed.
- Process Flow Diagrams and Heat and Material Balance have been used to develop Corrosion Loops and assigning Degradation Mechanisms for each corrosion loop.
- Velosi has used PID to reflect the demarcation of Corrosion Loops from PFDs.
- Velosi has developed Corrosion Loop Description Document for each corrosion loop marked on PFDs.
- Velosi has used Asset Register to group Piping in a piping circuit and mark the boundary of each piping circuits on PID and developed Piping Circuit Drawings.
- Velosi has marked Inventory Groups with clear boundaries on PFDs.
- Velosi has used Corrosion Loops with certain Degradation Mechanisms to identify critical process parameters and Integrity Operating Windows for each loop.
- Velosi has developed SAP template to create assets in SAP.
- Velosi has developed SAP Templates to link the lines with Superior Equipment (Piping Circuits)
- Velosi has developed RBI Templates to perform Risk Assessment and Generation Inspection Plan in GE Meridium.
- Velosi Prepared SAP Templates to create work orders for Inspection Tasks.
- Velosi has developed 580 Corrosion Loop Template for create and link corrosion loops with Piping circuits in GE Meridium.
- Velosi created CML markup drawings to highlight Inspectable locations.
- Velosi developed TML Template as per CML markup drawings and created TML Structure in GE Meridium.
- Velosi highlighted and de-activation Old Piping Circuits and Inspection Tasks in GE Meridium and SAP.
Outcome
Velosi’s team of expert individuals successfully conducted Risk-Based Inspection (RBI) study for PetroKemya OLEFINS-1/2/3 Plants utilizing APMS Mechanical Integrity (MI) module as per COMPANY requirements.
The Project was a successful completion, which 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 culminated in the delivery of 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.
Deliverables
Team Velosi developed and submitted the following deliverables:
Corrosion Loops Update
- Review of existing corrosion loops
- Develop / Update Material Selection Diagram for equipment and piping required to develop corrosion loops
- Create / Update Corrosion Loops
- Create / Update Corrosion Loops Diagrams (Markup PFD)
- Assign degradation mechanism per corrosion loops
- Update Corrosion Loops and Damage Mechanism in Meridium
Piping Re-Circuitization
- Review of existing Piping Circuit Master list
- Perform Re-Circuitization based on international / SABIC guidelines
- Create Piping Circuits Diagrams based on Piping and Instrument Diagrams
- Create Piping Circuits Master list
- Create / Review / Update Areas of Deterioration for Piping Systems Master list (injection points, mixing points, dead legs, Soil-to-air interfaces)
- Validate Piping Circuits / Areas of Deterioration for Piping Systems at the field
Data Migration in SAP
- Create / Update new Piping Circuits with new taxonomy in SAP using PMDB Software
- Deactivate redundant sub-circuits using PMDB Software
- Link lines to respective Piping Circuits using PMDB Software
Data Migration in Meridium
- Define CML’s for New Piping Circuits based on degradation mechanism and Areas of Deterioration for Piping Systems
- Create CML’s Masterlist for New Piping Circuits based on degradation mechanism and Areas of Deterioration for Piping Systems
- Create CML’s drawing for New Piping Circuits based on the degradation mechanism and
- Areas of Deterioration for Piping Systems
- Create / Update TML’s Groups / TML Points in Meridium TM Module based on defined CML Data
- Align old TML Data in Meridium to the New TML Structure in TM Module in Meridium
- Deactivate old Piping Circuits / Components In Meridium
RBI Assessments for NEW Piping Circuits
- Create new RBI Components for all new Piping Circuits in Meridium
- Link RBI Components to respective Corrosion Loop in Meridium
- Develop Inventory Groups for all Piping Circuits
- Establish new consequences for all new piping circuit
- Conduct RBI Reassessment for all New Piping Circuits (include RBI check Quality
- List in All Assessments)
- Develop and review a new Inspection Task in Meridium.
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