This area of investigation was directed toward addressing the impact of Instrumentation practices on the Utility Units’ Asset Management Program. Table lists the issues addressed and the resultant findings.
INSTRUMENTATION ISSUES | PLANT INTEGRITY MANAGEMENT
|Grounding System testing and inspection.||A grounding resistance measuring instrument is not available with Safaniya Electrical and Instrument E&I operations and maintenance department. E&I operations observes and resolves grounding fault issues based on experience|
|Some field instruments and their associated tubing lack structural support.||Lack of proper support could result in damage to instruments or cause inaccurate readings.|
|Partial on-line stroke testing of ESD valves is used in lieu of full stroke testing.||ESD on-line partial stroke testing should be considered as a complement to full stroke testing and not “in lieu of”.|
|Instrument technicians do not rely in maintenance history records in SAP as an aid to trouble shooting problems due to the lack of previous repair information entered in the system||Access to previous repair/calibration data can improve technician productivity and enhance instrument reliability though root cause analysis of problems.|
|Test equipment are not calibrated by third-party agencies||Independently calibrated test instrumentation provides a high level of confidence that correct measurements/ readings are observed and recorded.|
The key findings from the Instrumentation area are summarized as follows:
• A grounding resistance measuring instrument is not available with Safaniya E&I operations and maintenance department. E&I operations observes and resolves grounding fault issues based on experience. Recommendation: Test equipment to measure the ground resistance with valid calibration certificate should be provided to the operations and maintenance departments. It is also recommended that the ground resistance be checked periodically.
• Partial on-line stroke testing of Emergency Shut Down (ESD) valves is used in lieu of full stroke testing. A partial or full stroke test on a yearly basis is recommended. If a 1 year full stroke test cannot be made, then a SIL assessment and verification should be performed to calculate the required test interval.
• Test equipment is not calibrated by third-party agencies. Recommendation: As a “best practice”, a program for independent calibration of test equipment should be developed and implemented.