Process Safety Management
- Description
- Services
- Profiles
- Experience
You are about to embark on a new capital project. Are you confident in the quality of your engineering information?
Many refining and petrochemical plants struggle with a mountain of process safety and engineering information. This critical information is often scattered in file rooms, drawers or legacy applications. Compounding the problem are multiple versions of the same information housed in maintenance, engineering, safety, operations and other functional areas. What’s more, the information is often recreated and revalidated over and over again by different disciplines with different needs.
Siemens understands these issues and the negative impact they can have on your operations. We have the solutions to optimize your business decisions.
RBI/MI and Offerings & Services
As process facilities around the world age, optimizing mechanical integrity (MI) programs becomes more and more critical. This has driven a distinct shift towards more strategic and proactive analyses that rigorously assess the condition of process equipment. Evaluating the remaining life, reliability and life cycle cost of new and existing equipment helps ensure that inspection data and techniques are optimized for the current business environment.
Whether you’re optimizing operations with gap analyses, implementing an inspection data management system (IDMS), starting a risk-based inspection (RBI) program or simply building a foundation for accurate, accessible process safety information (PSI), Siemens mechanical integrity offerings are designed with flexibility in mind.
Offerings & Services
- Inspection Program Management
- Inspection data management services (UltraPIPE)
- Inspection services and planning - Mechanical Engineering Services
- Pressure vessel design & rerate
- Pipe stress & vibration analysis
- Materials and corrosion analysis
- Fitness-for-service - Risk-Based Inspection
- RBI program development
- Software selection
- Risk analysis and implementation
- Evergreening
- RBI Training
PHA and Services
Our process safety and risk assessment portfolio extends from onshore to offshore and upstream to downstream. Studies may be performed on a stand-alone basis or as part of an integrated strategy combined with other service offerings.
Siemens facilitates and supports Process Hazard Analysis (PHA) studies worldwide. We have experienced facilitators, scribes and participants who have extensive knowledge of industry standards and codes to assist the client in identifying and resolving potential safety and operability hazards, as well as major items that may affect the project’s detailed design, schedule or cost. We have an extensive knowledge of industry standards and codes, such as 29 CFR 1910.119, API 14C/14J and API RP 75.
Services
- PHA and revalidation
- Facility citing studies
- Human factors analysis - Hazard and Operability (HAZOP) studies
- What-if analyses
- Checklist reviews
- Hazard identification studies
- Conceptual design risk assessments (CDRA)
- Layers of protection analyses (LOPA)
- Safety integrity level (SIL) reviews
MOC and Services
Management of Change (MOC) is one of the most critical elements of OSHA 19010.110 PSM Standard, which requires facilities to establish and implement written procedures to manage all changes and hazards newly introduced to a process. An effective MOC process is the cornerstone for keeping all Process Safety Information (PSI) and related review up-to-date in refineries and plants.
Services
- MOC best-in-class workflow development and refinement
- MOC workflow conversion from paper-based to electronic system (using PS Change Manager)
- MOC coordination services
- MOC audit services
- MOC engineering support services
- MOC/PSI documentation audit and update services
RBI/IMI Profiles
| Client | Project Description | Scope of Work |
| A Major U.S. Refinery | Risk-Based Inspection: Siemens was tasked to implement an RBI program at this facility which would provide an organized and accessible system for the inspection and maintenance of all plant fixed equipment (including piping) such that analysis results are more precise, potential failure is more accurately predicted and prevented and program costs are managed more effectively. | Siemens upgraded existing RBI models into new API RBI V7. Consultants fully implemented an RBI program on units without previous RBI assessment into API RBI V7. Siemens facilitated inspection planning meetings and created evergreen RBI models and inspection plans per those meeting results |
| A Major International Petrochemical Company | Risk-Based Inspection: Siemens was responsible for providing an organized and accessible system for the inspection of all fixed equipment and piping such that analysis results are more precise, potential failure is more accurately predicted and prevented and program management costs are significantly reduced. This also included a complete RBI analysis and inspection plan for all equipment in the in-scope units of the complex, along with an emphasis on the development of a long-term RBI and an evergreen program. | Siemens consultants coordinated data reconciliation, inspection planning review and development, training, risk analysis, risk mitigation, piping circuitization and successfully conducted a corrosion study. |
| A Major International Chemical Company | Mechanical Integrity: Siemens performed a mechanical integrity audit of the facility, focused on the applicable requirements of OSHA’s PSM of Highly Hazardous Chemicals regulation (29 CFR Part 1910.119) as they apply to this company. Most companies perform internal audits on a regular basis, but there is much value added by contracting the objective help of a third party organization to perform this service. | Siemens performed an audit of the ICS Manual and procedures, and conducted employee and contractor interviews and discussions. Siemens consultants coordinated audit-records, created on-site observations, and issued a final report that concluded consultants’ findings. |
PHA Profiles
| Client | Project Description | Scope of Work |
| Major global onshore facility | HAZOP and SIL | Siemens provided a facilitator and scribe to perform a HAZOP study for an onshore gas facility in Angola. This lasted several weeks and a full detailed HAZOP report was provided. Siemens also performed three follow-up studies and a SIL verification study for the project. |
| Major U.S. onshore facility | PHA process | Siemens personnel managed the PHA process at a Midwest refinery, including facilitation services and resolution tracking. |
| Major U.S. onshore facility | LOPA study | Siemens facilitated a LOPA study and provided a report for a new gas plant project in the U.S. Once the required safety integrity levels had been established, a SIL verification study was performed to document as designed levels and recommend strategies for enhancements as required. |
MOC Profiles
| Client | Project Description | Outcome |
| Major U.S. refinery – multiple facility | Transformed a paper-based MOC system into a robust web-based, fully configurable system accessible by refinery personnel at multiple sites. | Provided accessibility and status visibility to all refinery personnel, including corporate, leading to a reduction in open items due to visible accountability. This led to an increase in closed action items, resulting in more expedient refinery safety improvements. |
| Major Chemical Plant | Provided MOC coordination services to support and audit all process safety information impacted by change in the plant. This also included all field verification of change. | Provided improved reporting on MOC status. Also provided audit reports, which included gap reports with recommended corrective actions. Ensured 100% audit of all process safety information impacted by MOC. This led to improvement in the plants process safety documentation and initiated target training for personnel in areas that needed improvements. |
| Major U.S. Gas Plant | Developed a best-in-class MOC workflow and an electronic MOC application. Additionally, provided MOC auditing and verification steps to ensure that the change activity adequately identified impacted process safety documentation, and that changes in the field were made according to the approved design. | Provided an MOC workflow that fit well with the facility’s current operations and added much needed oversight to ensure that the impact of the change was properly identified and updated. This led to a decrease in the number of unplanned shutdowns and incidents in the plant. |
| Major U.S. Chemical Company | Transformed a paper-based MOC system into a electronic management of change system accessible by all plant personnel. | Provided accessibility and visibility to all plant personnel leading to a reduction in open items due to visible accountability and increased awareness of changes taking place in the plant. This led to increased ownership of personnel in understanding and supporting the change process, thus resulting in improved overall plant performance. |
| Major U.S. Pipeline Company | Transformed a paper-based MOC system into an electronic management of change system accessible by plant personnel at five sites. | Provided an MOC program that helped the facility meet the regulatory requirements of the OSHA PSM Standard and improved business operations by streamlining the change process by adding required reviews and approvals by key plant personnel prior to the change being implemented. This led to better utilization of skilled plant personnel and an increase in the number of MOCs closed in the facility. |
RBI/MI Experience
| Client | Description |
| Amerada Hess | Third Party Data Conversion |
| BP Americas Production | UltraPIPE Audit |
| Bureau Veritas Bureau Veritas / Qatar Petroleum | RBI Implementation |
| ConocoPhillips | UltraPIPE Implementation |
| Delek | Third Party Data Conversion |
| Dow | Third Party Data Conversion |
| Duke Energy | UltraPIPE Software Training |
| Ineos | UltraPIPE Software Training |
| Motiva Enterprises LLC-Refining | RBI Implementation |
| Navajo Refining | UltraPIPE Software Training |
| Petrojam | UltraPIPE Implementation |
| Reliant Energy | UltraPIPE Implementation |
| Rhodia | UltraPIPE Implementation |
| SIPChem IMC | RBI Implementation |
| Sunoco | UltraPIPE Implementation |
| OxyVinyls | UltraPIPE Audit |
| PetroStar | UltraPIPE Software Training |
PHA Experience
| Client | Description |
| Al Khaleej Gas | HAZOP |
| AndesPetro | HAZOP |
| CB&I/Chevron | HAZOP and LOPA SIL verification |
| CITGO | PHA process management |
| Enterprise Products | LOPA and SIL verification |
| Southern Union | HAZOP Acid gas compression PHA Amine unit PHA |
| RasGas / EMDC | HAZOP |
| WGI / EMPCo | Gas development OSBL HAZOP |
| WRB/ConocoPhillips | PHA revalidation and LOPA |
MOC Experience
| Client | Description |
| BASF | Workflow conversion from paper-based to electronic system Maintenance support |
| ConocoPhillips | Coordination services Engineering support services Workflow conversion from paper-based to electronic system |
| ExxonMobil | Coordination services |
| Koch | Workflow development Engineering support services Coordination services |
| Millenium Chemicals | Workflow development Maintenance support |
| Qatargas | Change lifecycle management workflow development |
| Southern Union Gas Services | Software implementation Maintenance support MOC training |
| Sterling Chemicals | Auditing services Coordination services Engineering support services |
| Teppco | Workflow conversion from paper-based to electronic system |
| Valero | Auditing services |
| Valero McKee | Workflow development Software development |