Session: OAC-06-03 Continued Safe Operation of Existing Assets - 3

Paper Number: 109158

109158 - Piping Integrity Program at Petrochemical and Refinery Plant 

Piping Integrity Program was established to undertake frequent issues of leaking related to piping integrity which have contributed to a huge production loss at Petrochemical and Refinery plants in Malaysia. Based on the Root Cause Failure Analysis conducted, most of the incidents happened due to Ineffective operation planning and execution. Hence, a specific Piping Integrity Program was developed to address these issues. The program covers the development and implementation of periodic in-service inspection and condition monitoring program, performance monitoring, roles, and responsibility, and assurance program for process piping at plant. The main objective of establishing the Piping Integrity Program is to effectively manage process safety and business risk, standardize asset registration, inspection record and database management, inspection planning development approach and finally reach sustainable integrity program. Management commitment and support, proper planning, establishment of piping integrity program masterplan, program review, optimization, resources competency and understanding of piping damage mechanism is the key to the efficient piping integrity program. Amongst the strategy includes risk-based inspection approach (e.g., high risk piping, deadleg, injection/mixing point, normally no flow piping) and special emphasize inspection program (e.g., Corrosion Under Insulation, temporary repair, critical valve, piping component such as expansion joint bellow, spring support/hanger). Development of comprehensive inspection pack that consist of inspection reference plan, scheme of examination and mark-up isometric drawing/P&ID with respective Condition Monitoring Location (CML) significantly contribute to extensive coverage and yet cost-effective piping inspection.

Keywords: Piping integrity program, risk-based inspection, special emphasize inspection.

Presenting Author: Long Zulkarnaen Long Zainudin PETRONAS

Presenting Author Biography: Long Zulkarnaen is currently leading and managing the Asset Integrity Management activities including the implementation of Risk Based Inspection (RBI) and the application of a new technology in Asset Integrity field. With an educational background of a Master’s degree in Industrial Management from the University of Cambridge and a degree in Mechanical Engineering from the Universiti Teknologi PETRONAS, he is currently managing the Asset Integrity portfolio for Downstream Business in PETRONAS.

Authors:

Ahmad Exsan Othman PETRONAS
Long Zulkarnaen Long Zainudin PETRONAS