Documente Academic
Documente Profesional
Documente Cultură
Issue Date
Doc. No.
RP 32-3
October 1998
Document Title
APPLICABILITY
Regional Applicability:
International
AMENDMENTS
Amd
Date
Page(s)
Description
___________________________________________________________________
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
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RP 32-3
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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.
RP 32-3
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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)
(b)
(c)
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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)
(b)
(b)
(c)
(d)
(e)
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2.5
(f)
(g)
(h)
(i)
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)
(b)
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(b)
(c)
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.
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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)
(b)
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4.
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
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5.
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)
(b)
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(c)
(d)
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)
(b)
(c)
(d)
The age of the item and the length of time it has been in
commission.
(e)
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.
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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)
(b)
Inspection Grade 2
This Grade should be applied when the conditions of service are such
that:-
5.2.3.4
(a)
(b)
Inspection Grade 3
This Grade should be applied when the conditions of service are such
that:-
5.2.4
(a)
(b)
(c)
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(b)
(c)
(d)
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)
or
(ii)
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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
(b)
(c)
(d)
(e)
(f)
That the Inspection Grade is reviewed and a date set for the
next thorough inspection.
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5.4.2
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
10%
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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)
(b)
(c)
(d)
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5.5
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)
(b)
5.5.3
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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)
(b)
(c)
Replacement Equipment
(a)
(b)
(b)
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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
(b)
(c)
(d)
Thermal cycling.
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6.
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)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
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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)
(b)
(c)
(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)
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7.
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
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.
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REVIEW
PER. FOR
Grade 3 ***
RP 32-4
Grade 0
Grade 1
Grade 2
Grade 3
(month)
36
48
96
120
84
24
48
72
36
48
96
144
84
48
72
108
144
96
Gas holders
36
48
120
240
108
60
72
108
144
96
Lifting Equipment
See
BP Group
RP 32-4
Section 4
Storage Tanks
See
BP Group
RP 32-4
Section 5
Heat Exchangers
36
48
96
144
84
Piping Systems
36
48
96
144
84
Fired Heaters
24
48
72
See
Report
ESR.97.ER. 089*
See
BP Group
RP 32-5 &
RP 32-6
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
RP 32-3
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APPENDIX A
DEFINITIONS AND ABBREVIATIONS
Definitions
Standardised definitions may be found in the BP Group RPSEs Introductory Volume.
class:
competent person:
enforcing authority:
engineering function:
equipment:
inspection:
inspection function:
inspection engineer/inspector:
management:
operating centre:
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surveyor:
thorough inspection:
(b)
measure the rate and identify the type and cause of wear
and deterioration.
(c)
(d)
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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
BP Group Documents
BP Group RP 32-1
BP Group RP 32-2
BP Group RP 32-4
BP Group RP 32-5
BP Group RP 32-6
*ESR.97. ER.089
RP 32-3
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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
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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
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
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
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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.
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C.3.2
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
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.
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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
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
Response Form
Responses by discipline
engineers to given prompts.
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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
C.4.1.2
C.4.1.3
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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 RFs and PIIFs 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.
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To allow the chairman to familiarise himself will the plant items under
review, the collated RFs and PIIFs 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
Process Overview
Responsibility for completion of this stage lies with the Process
Engineer.
With reference to the system FDX and EFDs, 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 EFDs, 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
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Inspection Overview
Responsibility for completion of this stage lies with the Inspection
Engineer.
With reference to the system FDX and EFDs, 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 EFDs, 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.
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Working from the list of equipment items identified for study. Each
plant item or group of plant items are identified on the EFD/P&IDs.
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
C.5.7
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C.6
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.
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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
C.7.2
C.7.3
C.7.4
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PAGE 37
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
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
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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.
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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
C.8.2
C.8.3
C.8.4
C.8.5
C.8.6
C.8.7
C.9
RP 32-3
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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
C.9.2
C.9.3
RP 32-3
INSPECTION AND TESTING OF IN-SERVICE CIVIL AND
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PAGE 41
ITEM
REP AIRS?
PMP?
MATL of CONSTRN
FLOW ?
PRE SS?
TEMP ?
LEV EL?
REA CTION?
C.10
Page 1 of 2
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PAGE 42
OTHER?
MAINTENANCE?
UPSET CONDS?
NORMAL CONDS?
SHUT DOWN?
START UP?
EMISSIONS?
CORROSION?
POWER?
ITEM
Page 2 of 2
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PAGE 43
C.11
FORM PIIF
Job Engineer
Win No:
Description:
Normal Operation
Inlet Pressure (Bar):
Inlet Temperature (Deg C):
Upset Conditions
Inlet Pressure (Bar):
Inlet Temperature (Deg C):
TISCHUK Details
Contents:
Capacity (m3):
Location Within Plant (1-3):
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):
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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/
/ETHYLENE GLYCOL/
/PHTHALIC ANHYDRIDE/
/ETHYLENE OXIDE/
/POLYETHYLBENZENE/
/ETHYLENE/
/POLYETHYLENE/
/ETHYLENEDIAMINE/
/FLUORINE/
/POLYPROPYLENE/
/POLYSTYRENE/
/ETHANOL/
/ETHYL ACETATE/
/ETHYL CHLORIDE/
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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/
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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
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
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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 Engineer
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C.12
Example Review
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 :
:
By
:
Date
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