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Insurance Risk Survey Eleme Petrochemical Company limited

18th May 2011

The Questions:
Underwriters require answers to 2 questions:
How Big (Size of loss) How Likely (quality of risk)

General Points:
Huge improvement in the site since 2004 Staff competency and enthusiasm vastly improved Financial resources much more widely available Procedures being improved but still some way to go Response to recommendations patchy

General Philosophy:
Prevent incidents from happening Failures occur when the slices of cheeses are badly aligned.

Beware Iso Standards:

Below is an ISO 14000 Certified site:

Previous Recommendations:
Are a measure used by underwriters to monitor risk improvement Response are out of date and not always accurate. Some recommendations appear to be unconsidered.

New Recommendations:
SIMOPS Permit to Work Corrosion under insulation Wafer valves Preparation of RPI Maintenance of drains Fireproofing Bolting of Flanges Trip bypass register

Develop a SIMOPS procedure for current and future construction activities to cover, as a minimum: Separation of construction and operating facilities Tie ins Communications and emergency response

Permit to Work System:

Totally revise PTW system: Include individual JSA for job Revise PTW form All signatures on same side of paper No breaks in continuity Pre-inspections by ops people and maintenance before the start of work Post-inspections by ops people and maintenance before sign-off

Corrosion Under Insulation:

Areas where there is obvious damage Areas where materials of construction are more susceptible to external corrosion Ethylene storage areas

Wafer Valves:
Identify locations on hydrocarbon lines, especially liquid Either replace or provide insulation and stainless cladding

Preparation for RBI:

Mature plant with infant data
Prepare for time when data is available

Maintenance of Drains:
Drains in sphere area partially blocked with dirt and vegetation Blocked drains in process area
Discharge of sphere drains

Survey of damaged areas
Repairs where necessary Regular inspection by Survey department

Bolting and Flanges:

Training to avoid: Short bolting Incorrect blinds Incorrect materials of construction

'Short Bolting'
(ASME B31.1-1989 / 108.5 Bolting Bolt and Bolt Studs shall extend completely through the nuts.)
Short bolting is a term frequently used to describe the situation when a bolt is installed and the thread does not fully protrude through the nut. In order that the full strength of the nut is to be realized, it is vital that the bolt thread protrude through the nut. Failure to do so runs the risk that thread stripping will occur. It is common practice to specify that two thread pitches must protrude. Typically the first few pitches of the thread can only be partially formed because of a chamfer etc.

Trip bypass Procedure:

Change to a Permit type procedure Use an escalation process so that longer term bypasses are treamted as a management of change

Other Items:
Gas metering stations Use of mobile phones Use of seatbelts

More Information

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