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Risk Management and Use of Risk-Based Approaches in Inspection, Maintenance and HSE Analyses of NIS A.D STEINBEIS ADVANCED RISK TECHNOLOGIES GmbH Risk management and use of risk-based approaches in inspection, maintenance and HSE analyses of NIS a.d. plants Final Report for Package B (selected Annexes only) Stuttgart, Belgrade, July 7, 2010 Report title: Final report for Package B Costumer: NIS Petroleum Industry of Serbia Customer order Nr.: 45/609 Risk management and use of risk- Internal project Nr.: 10027 based approaches in inspection, Project title: maintenance and HSE analyses of Project start: October 1, 2006 NIS a.d. plants Project end: December 31, 2010 Subproject: Package B Applicable codes/standards: Workpackage: WP2.11 Date of order acceptance: Task: Date of completion: Additional contract info: Participants in the activity: Distribution (list): Participants / A. Jovanovic, D. Balos, P. Stanojevic, Distribution: B. Orlic, S. Eremic, O. Tot, M. Ilic, Z. 1 x NIS a.d. Pavlovic, D. Subotin, D. Jasin, R. 1 x Steinbeis R-Tech Guntrum, B. Stojanovic Author(s): A. Jovanovic, D. Balos, R. Guntrum Doc. Nr.: Version: 06 Date: July 7, 2010 Document Pages: 193 Annexes: 29 data: Status: Confidentiality: NIS, petroleum industry, risk management, API 581, risk based inspection, Keywords: reliability centered maintenance, Seveso, Safety report © Steinbeis Advanced Risk Technologies GmbH, Willi-Bleicher-Str. 19, 70174 Stuttgart, Germany STEINBEIS ADVANCED RISK TECHNOLOGIES GmbH Table of Contents List of Figures ................................................... vi List of Tables ................................................... viii 1 Management Summary Report .................... 1 2 Detail Technical Report .............................. 2 2.1 General part ............................................. 2 2.1.1 Introduction ................................. 2 2.1.2 General about NIS a.d. .................. 3 2.1.2.1 Activities ........................................... 3 2.1.2.2 History of the company ....................... 4 2.1.2.3 NIS in numbers .................................. 4 2.1.3 Pancevo Oil Refinery ..................... 5 2.1.3.1 General data ..................................... 5 2.1.3.2 Location of Pancevo Refinery ............... 6 2.1.3.3 Description of the plant ..................... 17 2.1.3.4 Safety of the plant ........................... 23 2.1.4 Novi Sad refinery ........................ 27 2.1.4.1 General data ................................... 27 2.1.4.2 Location description .......................... 27 2.1.4.3 Description of the plant ..................... 33 2.1.4.4 Safety of the plant ........................... 35 2.1.4.5 Description of processes ................... 37 2.1.5 Elemir Gas refinery ..................... 40 2.1.5.1 General data ................................... 40 2.1.5.2 Location description .......................... 40 2.1.5.3 Description of the plant ..................... 46 2.1.5.4 Description of processes ................... 49 2.2 About RBI / RCM methodology .................. 50 2.2.1 General ..................................... 50 2.2.2 Preparation of data base .............. 50 2.2.3 Identifying the Damage Mechanisms ............................... 52 2.2.4 Calculating the Likelihood of Failure52 2.2.5 Calculating the Consequence of Failure ...................................... 53 2.2.6 Determine the Financial Consequences ............................ 54 2.2.7 Calculating the Risk .................... 54 page ii STEINBEIS ADVANCED RISK TECHNOLOGIES GmbH 2.2.8 Remaining life assessment ........... 55 2.2.9 Developing an inspection plan ...... 56 2.2.10 Software used ............................ 60 2.3 General about HSE (HAZOP, Seveso II) methodology .......................................... 60 2.3.1 HAZOP ...................................... 60 2.3.2 Seveso II Directive ..................... 62 2.4 RBI / RCM Analysis and results for Pancevo Refinery ................................................ 63 2.4.1 The scope of analysis .................. 63 2.5 RBI / RCM Analysis and results for Novi Sad Refinery ................................................ 64 2.6 RBI / RCM Analysis and results for Elemir Refinery ................................................ 64 2.6.1 Executive summary ..................... 64 2.6.2 Introduction ............................... 66 2.6.2.1 Objective ........................................ 66 2.6.2.2 Scope ............................................. 66 2.6.2.3 Deliverables .................................... 67 2.6.3 Methodology .............................. 67 2.6.4 Performed activities .................... 67 2.6.5 Unit and process description ......... 68 2.6.6 Results of analysis ...................... 71 2.6.6.1 HAZOP Analysis Results .................... 71 2.6.6.2 Technical discussions ........................ 71 2.6.6.3 Management Systems Evaluation ....... 77 2.6.6.4 API 581 Qualitative (Unit-based) analysis results ................................ 79 2.6.6.5 API 581 qualitative analysis (component based) .......................... 79 2.6.6.6 RBI Detailed quantitative analysis ...... 81 2.6.7 Conclusions and recommendations 81 2.7 HSE (Seveso) report for Refinery Pancevo, Unit FCC ................................................ 83 2.7.1 Introduction ............................... 83 2.7.1.1 General ........................................... 83 2.7.1.2 Implementation of Seveso requirements ................................... 83 2.7.2 Information on site, plant and unit 84 2.7.2.1 General data ................................... 84 2.7.2.2 Location of Establishment .................. 84 2.7.2.3 Policy the company is pursuing .......... 86 2.7.2.4 Safety management system .............. 86 2.7.2.5 Hazardous materials ......................... 86 2.7.2.6 Meteorological data .......................... 86 2.7.2.7 External activities ............................. 86 2.7.3 Detail description ........................ 86 page iii STEINBEIS ADVANCED RISK TECHNOLOGIES GmbH 2.7.3.1 FCC unit S-2300 .............................. 86 2.7.3.2 Gas concentration unit S-2500 ........... 91 2.7.3.3 Flow charts ...................................... 95 2.7.3.4 Condition of the processes ................ 95 2.7.3.5 Hazardous material .......................... 95 2.7.3.6 Utilities and effects ........................... 97 2.7.4 Safety of the plant ...................... 99 2.7.4.1 History of accident ........................... 99 2.7.4.2 Hazards identified ............................ 99 2.7.4.3 Frequency of occurrence of hazards .. 105 2.7.4.4 Consequences of hazards ................ 106 2.7.4.5 Domino effect from Event TOP1 ....... 115 2.7.4.6 Summary of Hazard Analysis ........... 116 2.7.4.7 Measures to prevent or mitigate the hazards ......................................... 116 2.7.4.8 Measures to reduce the consequences of an accident ................................ 116 2.7.5 Risk assessment ........................ 117 2.7.5.1 Frequency ranking .......................... 117 2.7.5.2 Damage severity ............................ 117 2.7.6 Conclusions .............................. 118 3 RBI / RCM User’s manual ....................... 119 4 References ........................................... 120 5 Annexes .............................................. 121 Annex 1 Geographical position of Pancevo ............ 122 Annex 2 Industrial zone of Pancevo ..................... 123 Annex 3 General plan of Pancevo refinery ............. 124 Annex 4 Organization of Pancevo refinery ............. 125 Annex 5 General plan of Novi Sad refinery ............ 126 Annex 6 Substances in Novi Sad refinery .............. 127 Annex 7 Organization of Novi Sad refinery ............ 129 Annex 8 Responsibilities’ within management system in Novi Sad refinery .............................. 130 A.8.1 According to the requests of the standard ISO 9001:2000 (SRPS ISO 9001:2001) ............................... 130 A.8.2 According to the requests of the standard ISO 14001:2004 (SRPS ISO 14001:2005) ............................. 133 Annex 9 Novi Sad refinery – flow diagram of U 100 136 Annex 10 Refinery Novi Sad – flow diagram of U 200 137 Annex 11 Elemir Gas refinery in NIS Naftagas ......... 138 Annex 12 Integrated management system policy of NIS Naftagas ........................................ 139 Annex 13 Flow diagram of Elemir Gas Refinery ........ 140 Annex 14 Position of unit FCC in Pancevo refinery .... 141 page iv STEINBEIS ADVANCED RISK TECHNOLOGIES GmbH A.14.1 Blocks in Pancevo refinery ........... 141 A.14.2 General plan of refinery – position of FCC in Block 6 ........................... 142 Annex 15 QMS/EMS documents of RNP .................. 143 Annex 16 List of available drawings of FCC ............. 146 Annex 17 Main hazards in FCC .............................. 150 Annex 18 Block diagram of Pancevo refinery ........... 154 Annex 19 List of substances in Pancevo Refinery ..... 156 Annex 20 Flow diagrams ...................................... 160 A.20.1 FCC complex, Gas concentration unit - Propylene splitter section ............ 160 Annex 21 Safety data sheets for substances in FCC . 161 Annex 22 Damage estimates based on overpressure for process equipment (adjusted from CPS 2000) .................................................. 163 Annex 23 Summary of hazard analysis ................... 165 Annex 24 FCC: Bow-tie analysis result ................... 168 A.24.1 TOP1: Release from FA-2514 ....... 168 A.24.2 TOP2: Release from DA-2503 ...... 168 A.24.3 TOP3: Release from DA-2509 ...... 168 A.24.4 TOP4: Release from FA-2953 ....... 168 A.24.5 TOP5:
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