http://www.steinbeis.de
 
 
 
May 27, 2010
 
 
R-Tech software for RBI/RCM/RCFA and HSE/HAZOP analysis are audited and verified by auditor from Bayer.
The audit took place on May 26, 2010 at premises of R-Tech in Stuttgart. more
 
   

Risk management and use of risk-based approaches in inspection, 
maintenance and HSE analyses of NIS a.d. plants

 
 
Project Description
 
 
Acronym: RiskNIS
Start date: August 01, 2008
Total project value: approx. 2342k€
Project coordinator: Steinbeis Advanced Risk-Technologies,
Aleksandar, S. Jovanovic
Total number of partners: 2
Contact person (name/email): Aleksandar Jovanovic,
jovanovicrisk-technologies.com
Project webpage R-Tech/EU-VRi: http://www.risknis.risk-technologies.com/
Official webpage (coordinator): www.risk-technologies.com

 

The collaboration between NIS a.d and R-Tech in the area of Asset Management / Computerized Maintenance Management System (CMMS) has started in the first half of 2005 with the Pilot project aimed to provide the baseline needed for introduction of risk-based methods in inspection and maintenance, and risk management in NIS a.d. refineries and other operating units. 

Based on the results of the Pilot project, the collaboration continued with the project Risk management and use of risk-based approaches in inspection, maintenance and HSE in NIS a.d. plants (RiskNIS). The objectives of the project are to establish and implement an up-to-date asset management system which will allow mastering a cost effective maintenance, will be auditable to any regulatory inspections, and will ensure safety and reliability operation of present static and rotating equipment, as well as safety systems. 

The project covers following services: 
• Feasibility study, with the aim to determine basis for risk management implementation 
• Implementation of RBI, RCM and RCFA, including software Licensing, analyses
• Implementation of HSE, HAZOP and Seveso II Directive
• Training of NIS a.d. in RBI, RCM/RCFA and HSE/HAZOP/Seveso II and covering certification as well. 

These tasks are to be realized gradually, throughout three work packages (next to be ordered after acceptance of the results from the previous package):
• transfer of basic technologies and know-how for risk-based approaches in inspection and maintenance and HSE / HAZOP / Seveso II analysis 
• implementation package 
• full coverage package including analysis for all identified equipment of NIS. 

Results achieved up to the moment include: 

• RBI / RCM analyses for selected units in 2 oil refineries and 1 complete gas refinery (25 % of all equipment)
• HSE analysis for one complete unit of Pancevo Refinery and corresponding safety report according to the requirements of Seveso II directive [96/82/EC].
• training and education of employees on different organizational and professional levels (400+ participation).

 
   
 
 
Package B done
 
 
Work on Package B of RiskNIS project is in its last stage. Package B has included:
  • RBI / RCM analyses for selected units in 2 oil refineries and 1 complete gas refinery of NIS a.d.
  • HSE analysis for unit FCC of Pancevo Refinery,
  • training and education, including certification of employees on different organizational and professional levels.
 
 

Final reports are finished and they present results of RBI and RCM / RCFA analyzes for approximately 25 % of all equipment in three refineries of NIS a.d. HSE analysis of FCC unit in Refinery Pancevo and corresponding safety report according to the requirements of Seveso II directive [96/82/EC].

Full training and education of NIS employees has been realized as well. It has involved participants from different NIS a.d. organizational units. Final score of this training and education shows 400+ participation in different training, education or certification activities.

All these results of the Package B will further contribute to
  • control risk level by means of inspection processes and justified maintenance tasks optimization, contributing to site safety management and operational reliability of asset,
  • reduce plants hazard level by effective and timely inspection and maintenance works resulting with increased confidence in operation of the plant.,
  • align with the EU and other international regulations,
  • support to increase the turnaround cycles.
 
   
 
 
Package A done
 
 
Work within Package A of the project has started by the end of 2008 and finished in May 2009. The comprehensive critical review of the state of NIS assets (Basic Resource Document) has been made and the integrated web-based system for Risk-based inspection (RBI), Reliability Centered Maintenance (RCM), Root Cause Failure Analysis (RCFA) and Health, Safety and Environment analysis installed and applied on over 2,000 sample cases (units, systems, pieces of equipment – approx. 6 times more than initially planned). Approx. 300 participants of the corresponding training, education and certification measures have gained the professional skills needed to apply the methods and use the system.

Although the economic benefits were not foreseen for the Package A, the RCM/RCFA application of the system, on the example of maintenance-related investment (pumps) resulted in substantial savings.
Reed more about Package A and its results.

The main measurable economic benefits of the project are projected in packages B and C. Package “HSSE” will ensure compliance with the new regulation. Possible package “Aopt” would decisively improve the management system (Computerized Maintenance Management System - CMMS).

Continuation of the project in terms of packages and projects is foreseen as:

  • Package B will additionally provide the guided/supported implementation of the technology and tools provided in the basic package A. to a 20% of all equipment in NIS a.d. production units (the assumed most critical equipment) – ca. 5100 equipment.
  • Package C – assessing the complete assets of NIS (estimated approx. 30,000 components) and
  • Package Aopt with the goal of introducing the full-scale CMMS system.
 
   
 
 
Extention of the collaboration
 
 

The project RiskNIS has been extended in 2009 by 3 further projects dealing with
  • Environmental Risks
  • Legal Risks and
  • Project Risks.

Through the extension of the system for Risk-based inspection (RBI), Reliability Centered Maintenance (RCM), Root Cause Failure Analysis (RCFA) and Health, Safety and Environment analysis already developed and applied in NIS towards legal, project management and special environmental-specific has proven the viability of the integrated risk management solution, because all four systems use actually the same IT platform and the same set of IT web-based tools.

 
   
 
 
II phase of the collaboration
 
 
The collaboration between NIS a.d and R-Tech in the area of Asset Management / Computerized Maintenance Management System (CMMS) has started in the first half of 2005, and collaboration agreement signed in August the same year. Read more about this history.

The project second phase

is aimed to

  • control risk level by means of optimization of inspection processes and justified maintenance tasks, what will contribute to the site safety management and operational reliability of asset
  • increase the effectiveness of the inspection and maintenance activities, and
  • support increasing of the turnaround cycles.
It covers four separate parts:
  1. Detailed implementation plan (“feasibility study”)
  2. Implementation of the RBI, RCM and RCFA in NIS a.d. Plants:
    • I. Risk-based inspection (RBI)
    • II. Reliability Centered Maintenance (RCM)
    • III. Root Cause Failure Analysis (RCFA)

 
  Realization of the project is foreseen in 4 implementation packages, as shown schematically on the figure below:
  1. Package A - Basic package, covering total 330 pieces of equipment for RBI and RCM/RCFA analyses in three NIS a.d. refineries
  2. Package B - Proposed package, covering about 20 % of total equipment in three refineries
  3. Package C - Full coverage package covering all identified equipment in three refineries
  4. Package Aopt - Optional CMMS, covering full scale Computerized Maintenance Management System (CMMS)