Processus de maintenance VIVO Energy

Identification of Depot
Marquer tout
Critical HSSE &
Operational equipment les Equipment

Identification du Prepare Depot

niveau critique asset Register

Setting Equipment Depot Engineer prepare the

operational limits Pragma Maintenance annual preventive plan for
Management System equipment, tanks & facilities
according to Shell DEPs &
manufacturers
recommendations

Equipment Breakdown
Work order
Maintenance Depot
generated
Engineer operator

Depot Depot
Engineer / Manager
Specialised Depot Technician
Contactor Maint.

Sign-
Tech
Sign-off off

Generation of Monthly Reports

Closed work Back log Cancelled

orders Work Order

Asset Work hours Work orders

Report Expenditure distribution Logged
Distribution

VE S&D Engineering OU Distribution Depot Technicians &

Depot
Manager Manager Operation team
OU S&D Engineer
VE Distribution
Manager OU S&D monthly Maintenance performance
Monthly review
follow-up
 HSSE Barriers

There are two main types of barriers

1- The first type is critical equipment barriers

which are hardware.

Some examples of critical equipment barriers are:

alarms, shutdown or trips systems, relief systems, or gas detectors.

2- The second type is critical human barriers,

which are human interventions, such as:

 responding to an alarm,
 following a procedure, or
 activating emergency response equipment.

To ensure that barriers will continue to work the way they were designed, critical activities
are assigned to individuals.

Critical activities

• Critical activities maintain/assure the validity of a barrier

• Critical activities ensure that the holes (of the Swiss cheese) will not align

• At least one critical activity must be identified for each barrier

• Each critical activity must be assigned to one position and only one

• A critical activity must be documented with a frequency of implementation

examples of Critical Activities:

1. inspection of piping and vessels

2. function testing an Instrumented Protective Function (or IPF)

3. scheduled maintenance on equipment and routine checks of safety equipment

4. maintaining or updating procedures

5. emergency response training

 HSSE Critical Equipment
Criticalit HSSE Operation Limits
HSSE Function y Critical
Level Equipment,
Critical , if
impaired,
Equipment require
immediate
shutdown
of
equipment.
Pumps & pipes
Pressure Relief To protect the pipes & pumps from 1 √ The pre-load pressure
valve (pressure access pressure built. (differential pressure) is
relief valve (PRV), The pressure is relieved by allowing always between 2-2.5bar
pressure safety the pressurised fluid to flow from an above the maximal feed or
valve (PSV) and auxiliary passage out of the system medium pressure depending
safety valve.) on the nominal diameters and
elastomer involved
Trip system To protect the pipeline, ship /
refinery pump from over pressure by 2
avoiding sudden closure of normal
valves.
ESD To shut down electrical circuit / 1 √
switchboard in case of malfunction or
emergencies (fire, spill,...)
Pipe coating / Pipe Protection from climate & soil 3
insulation aggressiveness.
Cathodic Pipe Protection from soil 3
protection aggressiveness.
Pressure Gauge Provide control of equipment & Pressure gauges are classified
pipeline pressure to ensure adequate according to their precision, from
2
equipment operation (which need a grade A (permissible error of
0.1% of span) to grade D (5%
pressure range to operate) as well to error).
protect pipelines & hoses from
excessive pressure.

Tanks & bunded area

ATG Control the product level inside the
tanks especially during product 2
receipt to avoid overfill.
HLA To alert operators to shut down the
inlet valve and stop the product 1
receipt process to avoid tank overfill.
√
HHLA To activate to shut down inlet valve 3
and stop the product receipt process.
Temperature Provide accurate temperature of the
element product inside the tank accordingly
controlling the product pumping 2
process especially for high viscous
products (HFO,..) as well ensuring
accurate product delivery at the
 loading gantry.
PVV To open / close the passage of air set to within
into the tank and vapour off the tank 1 10% of the tank’s
to maintain the tank at the set +
√ maximum, safe working
pressure. pressure.
Internal floating Minimise the amount of low flash
roof products vapours (i.e. minimise 3
product loss by evaporation) and
minimise the effect on the
environment.
Tank paint Tank Protection from corrosion due 3
to climate effects (heat, humidity,...).
Cathodic Tank bottom Protection from soil 3
protection aggressiveness.
Bund Wall To contain accidental spill and 2
prevent it to spread all over the
installation.
Bunded area To prevent accidental spill to reach 3
flooring the soil & the groundwater.

Electrical system
Earthing system Protect the equipment, ‘= or < 10 Ω for all equipment
including strips, instrumentation, tanks,....& the 2 & buildings except for clean
cables, earthing personal from static electricity earth required for electronic
rods,.... equipment where it should be
< 2 Ω or as recommended by
supplier.
Switch boards To switch off electricity when there is 1 √
(circuit breakers, short circuit / load induced failure
overloads....) ranging from simple overload of the
motor
Phase sequence To protect equipment when there is a
source induced failure ranging from 1
voltage unbalance, phase failure or
√
phase reversal.
Stabilizer Protect electrical equipment from
sudden fluctuation of the electrical 1
current
√
(Generic for standalone JB or
Junction
integrated in the equipment).
boxes
All electrical circuits are enclosed in a 1
house strong enough to contain any √
spark / fire that may take place on
the inside.
Cable gland Ensure tightness of the cable / JB 1 √
connection and does not allow
vapours’ entry into JB.
Cable conduits / Protect cables from dynamic loads 3
trenches
Loading Gantry
Interlock system Protection from static electricity
(over fill & generated during product loading as 1
earthing system) well avoiding accidental overfill.
√
Containment To contain accidental spill and 3
area prevent it to spread all over the
installation

Drainage system
Oil Interceptor Treating effluent water to reduce the 2 HC content should be equal <
HC content to equal < 15ppm. 15ppm.
Interceptor Valve Ensure that the treated water from
oil interceptor will not be drained to
the public sewer or water streams
prior been analysed and that HC
content is within the acceptable
limits.

Security
CCTV To provide adequate internal (loading
gantry,..)& external (boundaries , 2
gate, external
surroundings,..)security controls.
Badge Allowing only authorized drivers / 3
Identification personal to enter the depots

Fire Fighting
Fire Alarm The system detects smoke / heat and 1 √
system activate siren to alert operators that
a fire is starting.
Fire water tank Tank to store water needed to 1 √
combat a worst case scenario fire for
a certain period of time.
Fire pumps Provide required water flow & 1 √
pressure needed for cooling & foam.
Tank cooling Provide water needed for cooling the 2 Min spray orifice = 6mm
rings tank shell & roof Pressure = 10.5 bar gauge
Ap rate (roof)= 1.7 Ap rate
(roof)= 1.7 lit/min/m2
Ap rate (Shell)= 17 lit/min/m
Fire water Network providing water under 1 √ 7 – 10.5 bar gauge
hydrant pressure
Tank foam Device to inject foam in the tank 1 √ Fixed roof (class 1)=4 lit/min/m2
chamber Fixed roof (class 2)=4 lit/min/m2
Base foam Device to inject foam in the tank 1 √ for 45 min application
injection (Gasoil tanks located in class 1 bund
should be treated as class1 tanks
Foam tank Tank to store foam concentrate 2
Foam To mix the foam concentrate with 1 √
proportions water to produce the foam
Foam manifold To direct the foam to the location
including valves where the foam application is
required.
Foam canons Equipment which direct the foam to
location where fire took place
1 √
2 Fixed roof (class 1)=6 lit/min/m2
Fixed roof (class 2)=6 lit/min/m2

Fire extinguishers Needed as a First aid for fire fighting 3

 Critical Operational Equipment

Criticality
Operation Function Level
Critical
Equipment
Pumps & pipes
Product pumps & In case of breakdown the operation will stop 1
motors

Loading Gantry
Loading arm The criticality level increase / decrease according to the 2
number of loading arm(s) / product.
Meter & Preset Ensure the required product quantity (volume) is 1
loaded in the road tank compartments.

Electrical system
Transformer Breakdown of the transformer will seize the operation 1
of the installation

IT System
Server & JDE System malfunction / down will seize the loading 1
process

Criticality Action Urgency

Level
1 Need immediate intervention
action to be closed within 8 hrs
2 Need swift intervention action to
be closed within 24 hrs
3 Need quick intervention
action to be closed within 48 hrs
 Mandatory Installations’ documents

The Asset Manager (Depot/ Bitumen / LPG filling plant& LOBP manager) is Accountable
for Creating, making available and maintaining the documentation for HSSE Critical
Equipment, including data and drawings that are critical to managing Process Safety.

Installations Drawings

The documentation must include as minimum the following drawings:

Drawings:

1. Plant / depot General layout

2. Classified zones
3. Mechanical & piping plan
4. Jetty / depot piping & details connection
5. Electrical (power, illumination & control) cable layout
6. ESD layout details
7. Process & Instrumentation diagram (P&Ids)
8. Fire fighting layouts showing water & foam diagram piping, manifold, valves,..., fixed
& mobile equipment
9. Fire alarm system layout

Engineering Procedures

A) Maintenance & Inspection procedure should include the following details:

1. Loading and Unloading Facilities (Road/Rail)

 Meter Inspection & Calibration
 Preset Meter and Counter
 Additive Dosing Inspection & Calibration
 Filters & Strainers Inspection
 Aviation Filter Inspection
 Product Unloading Facility
 Gantry Surveillance

2. Relief Valves
 Pressure / Vacuum Valve Technical Inspection
 Pressure Relief valves Technical Inspection

3. Pipes & Pipes' Fittings

 Pipeline Technical Inspection
 Valves Technical Inspection
4. Pressure Vessels
 Pressure Vessel Internal / External / surveillance Inspection
 Boiler Out of Service Inspection
 Boiler In-service Inspection

5. Hoses
 Dry-Break Coupler Inspection
 Marine & Terminal Hoses Visual test
 Marine & Terminal Hoses annual Inspection

6. Electrical
 Detailed Inspection of Motors
 Detailed Inspection of Earthing and Bonding
 Inspection - Electrical HV and LV Switchboards and MCCs
 Test Emergency Shutdown Device (ESD)
 Visual and Close Inspection of Electrical Equipment in Hazardous Areas
 Close Inspection of Electrical Standby and Battery Supply Systems
 Inspection of Portable Electric Equipment
 Visual Inspection of Power Transformers

7. Bund Wall
 Bund Walls & Compound Technical Inspection

8. Storage Tanks
 External routine inspection
 External detailed inspection
 Internal detailed inspection
 Tanks calibration

9. Additive System
 Blender Technical Inspection

10. Rotating Equipment

 Pump Technical In-Service & Out of Service Inspection
 Air Compressor Technical In-Service & Out of Service Inspection
 Pressure Vessel Technical In-Service & Out Of Service Inspection
11. Fire detection/alarm/fighting system
 Fire Detection System
 Fire Alarm System Test
 Fire Pumps (Weekly, monthly, annually), FLOW TEST
 FIRE WATER STORAGE TANKS
 Fire Extinguisher Inspection (6 months)
 SPRINKLER SYSTEMS 3-MONTHLY SURVEILLANCE & Annual Testing and
Maintenance
 FIRE MAINS AND HYDRANTS ANNUAL INSPECTION
 FIRE HOSES ANNUAL INSPECTION
 FOAM-WATER SYSTEMS ANNUAL TESTS
 Foam Proportioning System
 Foam Tank 5 & 10-yearly Maintenance
 Foam Concentrate Testing

12. Instrumentation & Automation

 Overfill Alarm Functional Test
 Level Gauge
 Level Gauge Temperature Verification

13. Drainage
 Inspect Monitoring Wells
 Technical Inspection Interceptors, Drainage & Pollution Control Systems
 Sample and Test Interceptor Effluent
 B) Inspection & testing procedure

Inspection carried out by independent third party experts

Tanks inspection (Internal & External) Frequency based on product stored & climate conditions
According to API 570 - class 2 process pipes.
Pipe Inspection Maximum inspection intervals:
Visual External: 5 years
Thickness measurements: 10 years
Electrical installation (including earthing system,…) Annual
Hose inspection (pressure, elongation & electric continuity) Annual

Fire alarm system Detector systems should be inspected in accordance

with manufacturers instructions

Fire Extinguisher Inspection Fire Extinguishers are to be inspected in accordance with

local regulations.(recommended every 6 months)

Fire Pump - Flow Test Annual Tests recommended for each Fire Pump Set
(electric motor and diesel powered) and Jockey Pumps.
should be tested by a certified testing laboratory, in
The foam concentrate accordance with regulatory requirements and
manufacturer’s recommendations.
Low pressure steam boilers are inspected, at minimum:
Boiler Inspection (a) Internally -- every two years, when physical
construction of the boiler allows; and
(b) Externally -- every two years, while under pressure.

Fixed pressure vessels, containing only air, , not

exceeding 20 cubic feet in volume, and operated at
Pressure Vessels (compressor tank,…) gauge pressures of not more than 200 pounds per
square inch must be inspected, at minimum:
(a) Internally – every six years, ; and
(b) Externally -- every six years.
Lifting equipment Lifts &
hoists inspection every 6 months + 4 yearly load test
derricks, fixed cranes, mobile cranes, FLT inspection every 12 months + 4 yearly load test
Vibration tests for rotating equipment (e.g. pumps) inspection every 12 months

C) Calibration procedure
1. Tanks calibration
2. PVV vent calibration
3. Meter calibration
4. Weighing scales calibration (Weighbridge)