ISPM Risk Assessment

August 30, 2017
© Reliability Dynamics LLC 2017 Reliability Dynamics
Industry Standard Solution for
Plant Maintenance (ISPM®)
ISPM Risk Assessment with RCM and PHA/HAZOP
Methods

August 30, 2017
ISPM Risk Assessment Methodology
Functionality incorporates RCM and Process Hazards Analysis (PHA)
 PHA is required for many United States processing facilities per OSHA CFR1910.119
 Center for Chemical Process Safety (CCPS) guidelines cover applicable methods, e.g.
HAZOP, What-if, etc.
Scenarios generated identify safeguards by discrete system ID (tag ID, PM plan
number, SJP number, etc.)
 This enables “live” monitoring of safeguards, which helps to ensure assumed risk reduction is
actually achieved
 Integration of ISO 14224 and RCM content can enable validation of scenarios by actual
operational experience

August 30, 2017
SAP RCM and PHA with ISO 14224 Notations
SAP Notification (Standard)

August 30, 2017
Customer Consequence Matrix

August 30, 2017
Customer Risk Matrices

August 30, 2017
SAP Risk Assessment
SAP Classification (Standard)

August 30, 2017
In-Place Risk
IW69 Report with SAP Business Graphics
Risk-ranking for facilities reviewed in this assessment
Factors in as-is conditions and all existing tasks/safeguards

August 30, 2017
Customer Assessment
SAP PHA+RCM

August 30, 2017
Assessment Overview
Approach
 RCM scenario development integrated with relevant Center for Chemical Process Safety
(CCPS) What-If Checklists
 Risk-based methodology
Facilities Evaluated
Distillation
 LP Refining Column Bottom Pump (P-1516A/B)
 HP Refining Column Feed Pump (P-1503A/B)
 HP Refining Column Reflux Pump (P-1504A/B)
 Topping Column Reflux Pump (P-1502A/B)
 LP Refining Column Reflux Pump (P-1506A/B)
Storage (MeOH product export)
 Product Methanol Transfer Pump (P-1801A/B)
 MeOH product custody transfer metering

August 30, 2017
Primary Finding
In the event of a significant leak from distillation pumps or their suction piping and
ignition of leaked product, operators may be unable to access block valves or
otherwise isolate inventory of the suction vessels
 Ramifications could be an extended pool fire and an external fire/explosion scenario for the
suction vessel or related vessels
 Operators may be unable to access block valves or otherwise isolate inventory of the suction
vessels
 Resulting facilities damage could potentially shut down Customer methanol production
operations for six months or longer
 The current risk level in the Customer risk matrix is 18 (Red Zone) (Table 3), which equates to
an annual exposure level of US $13,750,000 (Table 5)
 Implementation of this recommendation would decrease the risk level to 10 (Yellow Zone) and
reduce the annual exposure level to $137,500

August 30, 2017
Failure Effect Categorization (FEC) Details

August 30, 2017
RCM/What-if Results Snapshot

August 30, 2017
Recommended Facilities Modifications

August 30, 2017
In-Place Risk Reduction from New
Task/Safeguard Application

August 30, 2017
Customer Recommendations
Install remotely operated emergency block valves on distillation
pump suction lines, with automated activation
Install interlocks to shut down associated pumps on EBV activation
Consider changing methanol pump mechanical seals to a dual
configuration with a buffer pot
This recommendation is consistent with guidance by the Center for Chemical
Process Safety (CCPS). Per CCPS guidance, remote isolation of equipment
containing hazardous material is necessary to mitigate a release of hazardous
material when there has been loss of containment. Isolation can be accomplished
with the appropriate location of remotely operated emergency block valves (EBVs).
EBVs should be located…at the inlet of pumps from vessels with 10,000 pounds of
flammable material. All suction vessels have product inventories during normal
operation that exceed this threshold amount.

August 30, 2017
Suction Vessel Inventories

August 30, 2017
Recommendations for Retrofitting EBVs for
Distillation Pump Suction Vessels

August 30, 2017
Pump Seals Upgrade
Customer should also consider changing methanol pump mechanical seals to a dual
configuration with a buffer pot, either API 682 Plan 52 or 53A.
This recommendation is consistent with CCPS publication, "Guidelines for
Engineering Design for Process Safety," Clause 4.4.11.1, which states,
“Conventional positive-displacement pumps can handle highly toxic liquids if provided
with double or tandem seals…To prevent loss of process fluids, centrifugal pumps
should have a sealing system which consists of either double-inside or tandem
mechanical seals with a barrier fluid between the seals plus a seal-failure alarm.”

August 30, 2017
Dual Mechanical Seal Example

August 30, 2017
In-Place Tasks/Safeguards
Follow-up Recommendations
In the RCM workshop, we identified in-place risk for each component-level scenario, while
taking credit for tasks/safeguards that are currently being performed
 Descriptions for those tasks/safeguards were provided by Customer personnel, but no other
details were available
Recommend the following actions be taken:
 Add any tasks/safeguard that were missed during the assessment or any new
tasks/safeguards.
 A new inspection task was specified to address two internal corrosion scenarios related to the
MEOH Export Product Flow Meter
 Give all tasks/safeguards unique identifiers for tracking purposes, e.g. tag numbers for
equipment, procedure IDs for procedures, inspection plan numbers, etc.
 Confirm suitability, depth and breadth for each task/safeguard, e.g. adequacy of spare parts,
inspection plan details and results recording, procedural steps adequate and subject to an
approval chain, etc.

August 30, 2017
In-Place Tasks/Safeguards
Follow-up Recommendations
 Review task/safeguard risk reduction values for plausibility and make adjustments as needed.
 Use equipment reliability and maintenance data to validate risk scenarios and make
adjustments to tasks/safeguards
 Establish procedures for reliability maintenance and maintenance data collection,
including use of standard processes for technical hierarchy construction, malfunction
reporting, and PM condition reporting
 Recommend the ISO 14224 standard methodology for this purpose
 Use automation in the SAP to monitor and flag exception conditions

August 30, 2017
Thank You
Tony Ciliberti, PE
Reliability Dynamics LLC
Principal Engineer
Mobile: +1-574-274-3887
Office: +1-713-487-7271
Email: tony.ciliberti@rd-eam.com
Web: www.reliabilitydynamics.com

August 30, 2017
Tony Ciliberti
Principal Engineer | Reliability Dynamics | Linkedin: tciliberti
tony.ciliberti@rd-eam.com
Thank you

August 30, 2017
Relevant International Standards
ISO 14224:2006
Petroleum, petrochemical and natural gas industries -- Collection and exchange of
reliability and maintenance data for equipment
ISO 15926-2:2003
Industrial automation systems and integration -- Integration of life-cycle data for
process plants including oil and gas production facilities -- Part 2: Data model

August 30, 2017
Tony Ciliberti, PE
Principal Engineer
Thirty years experience as a reliability engineer in petrochemical, oil and gas, and
utilities
 Bachelor of Science, Chemical Engineering, Texas A&M University, 1987
 Licensed professional engineer
 SAP-certified Solution Consultant in Plant Maintenance
Four years with SAP Americas’ National Practice as a Principal Consultant and
Solution Architect
 SAP Top Talent: 2008-2010
 QVA Customer Focus: 2008
International and industry standards involvement
 ISO TC 67/WG4 PG1 (US expert): ISO 14224 - Collection and exchange of reliability and
maintenance data for equipment
 ISO TC 67/WG4 PG2 (US expert): ISO 20815 – Production assurance and reliability
management
 Center for Chemical Process Safety (CCPS) Process Equipment Reliability Database (PERD)
Project, PERD ERP Chair

August 30, 2017
Reliability Dynamics LLC
Company overview
Registered engineering company specializing in equipment reliability and
maintenance solutions for corporate software systems
Primary product is the Industry Standard Solution for Plant Maintenance
(ISPM®)
Current and recent Customers
Brunei Methanol Corporation
Precision Drilling
Pembina Pipeline
QGOG-Constellation
Maersk Drilling
Nexen Inc
Marathon Oil
Fortis Alberta

ISPM Risk Assessment

Recommended

Recommended

More Related Content

What's hot

What's hot (19)

Similar to ISPM Risk Assessment

Similar to ISPM Risk Assessment (20)

Recently uploaded

Recently uploaded (20)

ISPM Risk Assessment