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Copyright: Shell Brands International AG 2008
THE SHELL RISK BASED INSPECTION AND
SAFETY APPROACH OF PETROCHEMICAL
AND GAS INTALLATIONS
1st CEOC International Safety Seminar 3
rd
Feb 2010 Brussels
Sub-Brand zone
1st CEOC International Safety Seminar, 3 Feb. 2010, Brussels
Paul Slangen
Shell Projects & Technology
Netherlands
Contents
About Shell
Process safety - Asset management
h ll k d Shell Risk Based Inspection (S-RBI)*
Deliverables
Implementation experience
2
*S-RBI is a Shell trade mark
Topic or Session or Module Name
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Copyright: Shell Brands International AG 2008
SHELL
GROUP ACTIVITIES
App. 50 manufacturing & gas sites
UPSTREAM BUSINESSES
DOWNSTREAM BUSINESSES
Sub-Brand zone
SHELL PROJECTS & TECHNOLOGY
CORPORATE
Copyright: Shell Brands International AG 2008
SHELL
PROJECTS & TECHNOLOGY
Unit created in 2009, merging:
Global Solutions
Technology directorate of Exploration &
Sub-Brand zone
Technology directorate of Exploration &
Production
Safety and environment function
Contracting and procurement function
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Safety is No Harm - Goal Zero - within Shell
Work with a
valid work
permit when
required
Conduct gas
tests when
required
Verify isolation
before work
begins and use
the specified life
protecting
equipment
Obtain
authorisation
before entering
a confined
space
Obtain
authorisation
before overriding
or disabling safety
critical equipment
Protect yourself
against a fall
when working at
height required required equipment space critical equipment height
1
7
2
8
3 5
11
6
12 9 10
4
Do not walk
under a
suspended load
Do not smoke
outside
designated
smoking areas
No alcohol or
drugs while
working or
driving
Wear your
seat belt
While driving, do
not use your phone
and do not exceed
speed limits
Follow prescribed
Journey
Management Plan
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Managing Process Safety
Bow-Ties are used for:
the identification and risk assessment of HSE hazards
the evaluation and implementation of control and recovery measures and
to document that major HSE risks have been reduced to as low as reasonably practicable (ALARP).
Threat
Corrosion Barrier
Material
Barrier
Inspection
Barrier
Operating
Window
Hazard
Hydrocarbons
Barrier
Emergency
Response
Barrier
Gas
detection
Barrier
ESD
Consequence
Small fire
Top Event
E l i /Fi
Cause Effect
Scenario
Loss of containment
Threat
Degradation
Barrier
Material
Barrier
MOC Barrier
Operating
Window
Barrier
Emergency
Response
Barrier
Gas
detection
Barrier
ESD
Consequence
Small fire
Explosion/Fire
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Link to Manufacturing Work Processes
Bow-Tie
ESP
ME
Proactive Processes
Execution Processes
RRM*
RCM
Bow-Tie
ESP
RBI
IPF
Barriers
needed
TA
RRM
Critical
Activities
needed to
maintain
barriers
RCM
EI
ESP
Emergency Response, MOC, Competency Mgt., Permit to Work, Document Management, HSE
Compliance, Contractor Mgt., PPE
Critical activities needed to maintain barriers
The linkages between the other work processes is also very important!!
*RRM is a Shell trade mark: Risk & Reliability Management ; ME: maintenance execution; TA: turn around;
EI: equipment integrity; ESP: ensure safe production
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Shell RBI has a strict definition
Is a risk-baseddecision support process
structured and multidisciplinary
to determine and document, cost-effectively,
The optimuminspection requirements
of pressure containing equipment in its operating context
and safeguards integrity
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S-RBI requires regular updating
(evergreening)
Asset Integrity
Database
Asset Integrity
Database
Corrosion Loop
Assessment
Corrosion Loop
Assessment
Including IOW* Including IOW*
Remnant Life
Calculation
Remnant Life
Calculation
Criticality (Risk)
Assessment
Criticality (Risk)
Assessment
Analyse results
& Document
Analyse results
& Document
Initiate
Corrective
Actions
Initiate
Corrective
Actions
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Assessment Assessment
Confidence
Rating
Confidence
Rating
Inspection
Interval & Tasks
Inspection
Interval & Tasks
Task Execution Task Execution
*IOW: Integrity Operating Window
Assessment of the Criticality (RAM)
H L MH H E E
Criticality
C
L
A
S
S
Very susceptible to
degradation
Susceptible to degradation
Susceptibility to Failure
M L M MH H E
L N L M MH H
N N N L M MH
no/slight
damage
minor damage local damage major damage extensive
damage
no/slight injury minor injury major injury single fatality multiple fatalities
no/slight effect minor effect local effect major effect massive effect
P
R
O
B
A
B
I
L
I
T
Y

C
Susceptible to degradation
under normal conditions
Susceptible to degradation
under upset conditions
Not susceptible under any
forseen conditions
C
O
N
S
E
Q
U
E
N
C
E
C
A
T
E
G
O
R
Y
ECONOMICS (US$)
HEALTH & SAFETY
ENVIRONMENT
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RAM = Risk Assessment Matrix
N = Negligible L = Low M = Medium
MH = Medium High H = High E = Extreme
NEGLIGIBLE LOW MEDIUM HIGH EXTREME CONSEQUENCE CLASS
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S-RBI is documented & managed
Methodology Process Tool people gy p p
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RRM = process : people : tools = 40 : 40 : 20
Deliverables S-RBI
Corrosion Control Document per Unit
Corrosion loops (systems)
potential degradation mechanism potential degradation mechanism
integrity operating parameters
RBI study validity window
Summary S-RBI analyses
Criticality distribution
Focus on critical equipment and piping
Optimised Inspection Interval
Summary of equipment with intervals < TA interval
High level inspection plan
Follow-up actions and recommendations
Shared knowledge and buy-in by stakeholders
Auditable process (transparency)
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Implementation experience [1/2]
Study based on present knowledge and experience
Evergreen RBI in the run and maintain phase
Progressing insights failure (degradation) modes during
inspections and turnarounds
failure and incident investigations
Need for knowledgeable team members and shared
i f h i d ( d d d d ) experience from the industry (standards and procedures)
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Implementation experience [2/2]
Actions and recommendations
Interaction with other work processes, i.e EI, ME, TA, Interaction with other work processes, i.e EI, ME, TA,
ESP, MOC..
Competence of RBI facilitators
RBI knowledge (i.e. API 580, CEN)
Facilitation skills
Project management skills
Methodology skills
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How can CEOC play a role?
Inspection and certification bodies
Standardisation and guidelines
Certification
knowledge (i.e. API 580, CEN etc.)
facilitation skills
project management skills
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Copyright: Shell Brands International AG 2008
THANK YOU
Discover more at www.shell.com or contact:
paul.slangen@shell.com
Sub-Brand zone
Topic or Session or Module Name
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