1、 Managing Systems Integrity of Terminal and Tank Facilities Managing the Risk of Liquid Petroleum Releases API PUBLICATION 353 FIRST EDITION, NOVEMBER 2006 Managing Systems Integrity of Terminal and Tank Facilities Managing the Risk of Liquid Petroleum Releases Regulatory and Scientific Affairs API
2、PUBLICATION 353 FIRST EDITION, NOVEMBER 2006 Prepared under contract by SPEC Consulting, LLC, for API Joseph Burke, PE, CSP SPECIAL NOTES API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should
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5、ations may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims
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7、ese publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices. Any manufactu
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9、dard. Users of this Bulletin should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein. All rights reserved. No part of this work may be reproduced, stored in a
10、retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005. Copyright 2006 American Petroleum Institute
11、1-i FOREWORD This publication provides an overall approach for risk management, including the principles of risk management and an approach to risk assessment. It presents an industry approach to the management practices necessary to implement the principles of risk management and risk assessment fo
12、r terminal and tank operations. In addition, it illustrates a method for selecting environmental protection control measures from liquid releases based upon the control measures hierarchy presented in API Publication 340, Liquid Release Prevention and Detection Measures for Aboveground Storage Facil
13、ities. Although this document is intended for petroleum terminal and tank facilities associated with marketing, pipeline, and other facilities covered by API Standard 2610, Design, Construction, Inspection and Maintenance of Petroleum Terminal and Tank Facilities, and was developed to guide the mana
14、gement of terminal and tank facilities in evaluating cost-effective methods for protecting the environment, workers, and the public, it can be used in many ways, including the development of an overall corporate integrity/risk management program for terminal and tank facilities. Other potential uses
15、 include: Development of a corporate risk assessment methodology or utilization of the risk assessment methodology presented in the appendices of this document Motivation to consider modification of inspection intervals from those stipulated in API Std 653, Tank Inspection, Repair, Alteration and Re
16、construction, and API Std 570, Piping Inspection Code: Inspection, Repair, Alteration and Re-rating of In-Service Piping Systems Provision of a risk-based approach to screen, evaluate, and if appropriate, select control measures that may prevent, detect, or protect the environment from liquid releas
17、es of petroleum Provision of an API-endorsed, consistent, and repeatable approach to risk management of terminal facilities Provision of a tool for negotiating with regulators in regards to implementation of proscriptive control measures that may not provide cost-effective control of terminal risks
18、The approaches detailed in this document are not mandatory; they are intended as a guide for those desiring to implement and/or use a risk assessment. Typically, a risk assessment is performed when a facility is changing equipment or processes. The appendices of this document present optional method
19、s for conducting a risk assessment if a facility decides to do so. Other methods are available outside the scope of this document, or a company can decide to create its own method. API does not intend to imply sole endorsement of any particular method or that a risk assessment is required in all cas
20、es. The optional methods presented in this document are for demonstration purposes. This document is intended to be consistent with, but is not a substitute for, any applicable local, state, or federal regulations. Every effort has been made by the Institute to assure the accuracy and reliability of
21、 the data contained in the document; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or muni
22、cipal regulation with which this publication may conflict.i TABLE OF CONTENTS Section Page 1. INTRODUCTION1-1 1.1 PURPOSE AND OBJECTIVES 1-2 1.2 SCOPE . 1-2 1.3 TARGET AUDIENCE 1-2 1.3.1 How to Use This Document 1-3 1.3.2 Roles and Responsibilities.1-7 1.3.3 Training and Qualifications. 1-8 1.3.4 Go
23、vernmental Requirements. 1-8 1.4 APPLICABLE FACILITIES . 1-8 1.4.1 Petroleum Terminals . 1-8 1.4.2 Pipeline Tankage Facilities . 1-9 1.4.3 Bulk Plants 1-9 1.4.4 Lube Blending and Packaging Facilities . 1-9 1.4.5 Asphalt Facilities. 1-9 1.4.6 Aviation Service Facilities 1-9 1.4.7 Overlapping Faciliti
24、es Coverage . 1-9 1.4.8 Non-applicable Facilities. 1-10 2. TERMS, DEFINITIONS, AND ACRONYMS2-1 2.1 TERMS AND DEFINITIONS. 2-1 2.2 ACRONYMS. 2-4 3. REFERENCES AND STANDARDS.3-1 4. BASIC CONCEPTS OF RISK.4-1 4.1 PRINCIPLES AND PHILOSOPHY OF RISK 4-1 4.1.1 What Is Risk? 4-1 4.1.2 Likelihood of Occurren
25、ce 4-2 4.1.3 Consequence of Occurrence 4-2 4.1.4 Risk 4-3 4.2 RISK SCORING 4-3 4.2.1 Risk Matrix Development . 4-3 4.2.2 Quantitative Risk Analysis 4-5 4.2.3 Risk Reduction 4-9 5. RISK MANAGEMENT PROGRAM OVERVIEW5-1 5.1 GENERAL. 5-1 ii 5.2 DEVELOPING A COMPANY APPROACH TO RISK MANAGEMENT . 5-2 5.2.1
26、 Hazard Identification. 5-3 5.2.2 Risk Assessment Overview . 5-3 5.2.3 Risk Evaluation, Control, Management, and Mitigation. 5-7 5.2.4 Procedures . 5-8 5.2.5 Training . 5-8 5.2.6 Emergency Planning and Emergency Response . 5-8 5.2.7 Incident Investigation and Root Cause Determination 5-9 6. RISK ASS
27、ESSMENT.6-1 6.1 COMPANY RISK ASSESSMENT PROGRAM 6-2 6.2 TYPES OF RISK ASSESSMENT. 6-2 6.2.1 Qualitative Risk Assessment . 6-3 6.2.2 Quantitative Risk Assessment . 6-3 6.2.3 Semi-Quantitative Risk Assessment 6-4 6.3 PRECISION VS. ACCURACY. 6-4 6.4 THE ROLE OF INSPECTION IN RISK ASSESSMENT 6-4 6.5 RIS
28、K ASSESSMENT APPROACH 6-5 6.6 RISK ASSESSMENT TEAM 6-8 6.7 API PUBLICATION APPENDIX RISK ASSESSMENT DEMONSTRATION . 6-9 6.7.1 API Example Risk Assessment Method for AST Facilities 6-9 6.7.2 The Risk Scoring System 6-9 6.7.3 The Risk Matrix. 6-10 6.7.4 Steps in Conducting the API Risk Assessment Mode
29、l 6-11 6.7.5 Conducting Risk Assessment Decision-Making . 6-13 6.8 GATHERING, REVIEWING, AND INTEGRATING DATA . 6-14 6.8.1 Getting Started. 6-14 6.8.2 Data Sources 6-15 6.8.3 Identification and Location of Data. 6-15 6.8.4 Data Collection 6-16 6.8.5 Data Integration. 6-16 6.8.6 Data Gap Assumptions
30、6-16 6.9 RECORD KEEPING . 6-17 6.9.1 General Requirements . 6-17 6.9.2 Risk Assessment Methodology . 6-17 6.9.3 Risk Assessment Personnel . 6-17 iii 6.9.4 Time Frame . 6-18 6.9.5 Assessment of Risk . 6-18 6.9.6 Assumptions Made to Assess Risk 6-18 6.9.7 Risk Assessment Results . 6-18 6.9.8 Mitigatio
31、n and Follow-Up. 6-18 6.9.9 Codes, Standards, and Government Regulations 6-18 7. INTEGRITY ASSESSMENT7-1 7.1 METHODS OF INSPECTION 7-1 7.2 METHODS OF ASSESSMENT 7-2 7.3 ESTABLISHING RE-INSPECTION INTERVALS AND MITIGATING RISK. 7-2 7.3.1 Establishing an Inspection Strategy Based on Risk Assessment. 7
32、-2 7.3.2 Managing Risk with Inspection Activities 7-3 7.3.3 Assessing Inspection Results and Determining Corrective Action . 7-3 8. RISK MITIGATION8-1 8.1 GENERAL. 8-1 8.2 MITIGATION APPROACH AND OPTIONS 8-1 8.3 USING API PUBLICATION 340 . 8-4 8.4 SUMMARIZED EXAMPLES. 8-4 8.4.1 Mitigation of Potenti
33、al Releases at a Unit Level. 8-6 8.4.2 Mitigation of Potential Releases at the Facility Level. 8-9 8.4.3 Risk Mitigation at a Corporate Level 8-18 9. MANAGEMENT OF CHANGE9-1 10. PERFORMANCE MEASURES10-1 10.1 PERFORMANCE MEASURE CHARACTERISTICS. 10-1 10.2 PROCESS OR ACTIVITY MEASURES 10-1 10.3 OPERAT
34、ION MEASURES. 10-2 10.4 DIRECT INTEGRITY MEASURES. 10-2 10.5 PERFORMANCE MEASUREMENT METHODOLOGY. 10-2 10.6 PERFORMANCE MEASUREMENTINTRA-SYSTEM 10-2 10.7 PERFORMANCE MEASUREMENTINDUSTRY-BASED 10-2 10.8 PERFORMANCE IMPROVEMENT 10-2 11. QUALITY CONTROL.11-1 11.1 CHARACTERISTICS OF A QUALITY CONTROL PR
35、OGRAM 11-1 11.2 RISK MANAGEMENT PROGRAM AUDITS 11-2 iv Appendix A Optional Comprehensive Risk Assessment Method I .A.1 Appendix B Optional Qualitative Risk Assessment Method II .B.1 Appendix C Risk Assessment Workbook for Appendix A, Method I.C.1 v LIST OF FIGURES Page 1-1. Approaches to Using the D
36、ocument 1-5 1-2. Framework for Using This API Publication 1-6 4-1. Example Risk Matrix Showing Levels of Risk . 4-4 4-2. An Example Risk Matrix Showing Consequence-Aversion 4-4 4-3. Example of Risk Point.4-5 4-4. Example of Risk Plot for Multiple Scenarios 4-6 4-5. Example of a Cumulative Risk Curve
37、. 4-8 5-1. Risk Management Program . 5-5 6-1. Example Risk Matrix Showing the Results of the Example Case Including Users Bias to Consequence Aversion 6-11 6-2. Overview of AST Risk Assessment Process . 6-12 8-1. Hierarchy for Selection of Control Measures 8-3 LIST OF TABLES Page 4-1. Example of Ris
38、k Points for a System 4-6 4-2. Data for Accumulated Risk Plot 4-7 4-3. Example of Scenarios and Risk Scores for a System 4-9 6-1. Scoring System Example. 6-10 8-1. Data Table for Tanks Examined in Scenario 1 8-6 8-2. Likelihood of Tank Failure Calculation Results for Tanks in Scenario 1 . 8-7 8-3. C
39、onsequences of Tank Failure Calculation Results for Tanks in Scenario 1. 8-88-4. Tank Risk Calculation Results for Tanks in Scenario 1 8-9 8-5. Base Facility Risks 8-10 8-6. Example Types of Available Control Measures 8-11 8-7. Example Remaining Control Measures. 8-11 8-8. Option 1, High-Level Alarm
40、sRevised Overfill Risks . 8-12 8-9. Option 2, LinersRevised Overfill Risks 8-12 8-10. Option 2A, LinersRevised Risks for AG Piping however, they typically do not perform the risk assessment analysis detailed in the appendices without the proper training and experience. 1.3.1 How to Use This Document
41、 Users can benefit from this document in several ways. First, it gives readers a brief overview of a basic RMP that they can use to develop their own corporate program. This is the first step in establishing an RMS. Second, users can develop their own risk assessment method, or they can use part, or
42、 all, of the optional risk assessment approaches detailed in the attached appendices. Third, users can develop a relative ranking of risks for various items, and using the guidance provided in this document, establish a risk-ranking matrix that helps them identify risks that may require remediation.
43、 Fourth, the user can use the approach detailed in the optional appendices to screen potential mitigation measures that are presented in API Publ 340. Last, users are provided a workbook, forms, checklists, and worked examples to aid in implementing their program. From these examples, the user can s
44、ee the potential benefits in building a comprehensive Risk Assessment Program which meets the overall objectives of minimizing and mitigating the effects of liquid releases on the environment. Figure 1-1 illustrates the different approaches for using the document. The framework for using this docume
45、nt, outlined in Figure 1-2, is a step-by-step process that allows users to customize a program to fit their individual needs. It includes the following steps: Step 1Users develop an overall company RMP that includes the program elements presented in Sections 4 and 5. Step 2Users determine if they wa
46、nt to perform a risk assessment as part of their overall RMP. There are varying types and complexities of risk assessments as outlined in section 5.2.2 and Section 6. Users may also elect to use one of the optional risk assessment approaches outlined in this document. This publications optional risk
47、 assessment approach is briefly discussed in section 6.7, with detailed information and a workbook presented in the appendices. Step 3Users gather the appropriate facility information and data needed to develop an RMP and perform a risk assessment (if the user elects to perform a risk assessment), d
48、escribed in Sections 6 and 7. Step 4Performing the risk assessment requires determining the frequency or likelihood that a specific event will occur and the consequences if the event does occur (section 4.1). Step 5Once the risks are quantified by determining the likelihood and consequence, they can be ranked and evaluated (Section 4.2 and 8). Step 6Owners can determine, based upon their corporate principles, what risks, if any, require mitigation. This is discussed in Sections 5.2.3, 8, and 10. Step 7Mitigation measures are selected or screened for selec
