This area of investigation was directed toward determining which approaches may have been used by Saudi Aramco to determine the risk posed by equipment or piping to HSE, as well as risks to production. Table 3-3 lists the issues addressed and the resultant findings.
RISK MANAGEMENT ISSUES
|Does the plant have a specific risk matrix that is used consistently across the plant?||There is no formal risk matrix. The concept of risk is outlined in Guide Number 02-001-2009, Risk Assessment and Management A Guide for Managers.|
|Is everyone aware of the risk matrix and trained in its use?||A formal risk approach is not used in decision making.|
|What high-level approaches are used to determine equipment inspection, testing and maintenance requirements (e.g. Risk Based Inspection (RBI), Reliability Centered Maintenance (RCM), Safety Integrity Level (SIL) Reliability, Availability, and Maintainability
|No evidence that any of the indicated approaches had been used.|
|What are the main drivers for applying a risk approach to maintenance and integrity?||G26 has not performed the analyses. Operations designate equipment criticality by experience.|
|What approaches to risk analysis have been adopted?||No approaches have been formally adopted. SABP-G-017 10
Equipment Criticality Assessment lays out a procedure for developing equipment criticality.
|Who manages the processes?||N/A|
|What data were used to support the processes?||N/A|
|How well are the plant operating conditions and environment known?||Well known|
|How are deterioration mechanisms and failure modes identified and likelihood of failure determined?||Unknown|
|What data relating to plant reliability and failure history is available?||Equipment history is on SAP for review of each equipment item.|
|What information relating to the consequences of failure is available?||SAP includes failure codes and script describing the failure and repair. There is a Repair History Index (RHI) that is used to track how complete the finished work orders are filled in. Utility maintenance is doing better than operations in completing the WO per the RHI.|
|What factors determine the consequences of failure||Unknown|
|How are risks (criticality) of equipment ranked or categorized?||SABP-G-017 outlines a procedure concentrating on equipment maintenance and operating history, and Subject Matter Experts (SME). It is also a process for capturing SME knowledge before retiring. Utility has not implemented SABP-G-017.|
|What methods or factors are used to determine equipment inspection, testing or maintenance intervals||Unknown|
|Are special measures considered for equipment with high consequences of failure?||Unknown|
|What measures are in place to address the risks from deteriorating equipment||Preventive and corrective maintenance.|
|What procedures are used to minimize the risk to equipment prior to test or inspection?||Vibration monitoring of rotating equipment; cathodic protection|
|What procedures are in place to review the results of inspection, testing and maintenance and re-assess asset management requirements?||Unknown|
The key findings from the Risk Management area are summarized as follows:
• While a consensus equipment criticality assignment exists, there is no formal risk matrix.
The concept of risk is outlined in Guide Number 02-001-2009, Risk Assessment and Management, A Guide for Managers. Recommendation: The Safaniya GOSP should adopt the guideline; implementation of the guideline should be accomplished with the assistance of a third party to ensure consistency and objectivity.
• No risk management approaches (e.g., RBI, RAM, etc.) have been formally adopted for the Safaniya GOSP. Recommendation: SABP-G-017 10 Equipment Criticality Assessment which provides a procedure for developing equipment criticality should be adopted and implemented.
• While no formal processes for addressing risk assessment have been employed for the Utility Units, it was the impression of the assessment team that maintenance, operations, and engineering staff are aware of the relative importance and impact that the equipment and systems in the Utility Units have on Health, Safety, and the Environment (HSE) and production. Recommendation: The adoption and implementation of a formal risk assessment approach will allow for alignment of maintenance and inspection resources with the risk that each item of equipment poses resulting in a more efficient use of resources and potentially reducing overall costs.