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Introduction
Company
Bapco Refining
Industry
Oil & Gas
Products
Asset Reliability, Asset Strategies , Condition-Based Maintenance, Mechanical Integrity, Asset Performance Management
Key Highlights
- Leaders and users from Bapco - together with SMEs from GE Vernova - worked closely to define APM adoption gaps and the path for streamlined digital transformation.
- Intelligent alerts and dashboards enabled a more effective monitoring system to identify process safety bad actors and track any follow-up activities.
- Bapco Refining utilized the RBI capabilities in APM Integrity to mitigate risk and further extend the mandatory inspections periods.
Bapco Refining was established in 1929. After the first oil discovery in Bahrain, an inaugural refinery was set up in 1936 with a capacity of 10,000 barrels per day. Over time, Bapco Refining’s progress has been punctuated with expansions and technological advancements. Milestones include initiatives geared toward enhancing processing capabilities at Bapco’s refinery and enabling the transformation of Bahrain's crude oil into refined products for both domestic consumption and global trade. In 2024, Bapco’s refining capacity is at 267,000 barrels per day.
One of the largest projects undertaken in its 90+ year history was the Bapco Modernization Programme (BMP) to align with the Kingdom of Bahrain’s ‘Vision 2030.’ Key objectives of BMP include increasing refining capacity to 380,000 barrels per day, enhancing the product slate, improving energy efficiency (28 % improvement in the energy efficiency index), and emerging as one of the most competitive and environmentally compliant refineries in the region.
One of the largest projects undertaken in its 90+ year history was the Bapco Modernization Programme (BMP) to align with the Kingdom of Bahrain’s ‘Vision 2030.’ Key objectives of BMP include increasing refining capacity to 380,000 barrels per day, enhancing the product slate, improving energy efficiency (28 % improvement in the energy efficiency index), and emerging as one of the most competitive and environmentally compliant refineries in the region.
The Challenge
Prior to deploying the Health and Integrity applications in APM, Bapco Refining encountered the following challenges:
- Lack of an efficient monitoring system to identify process safety bad actors through Integrity Operating Windows (IOWs)
- Multiple data sources, and parameters to contextualize at the same time
- Lack of data integration; no direct linkage between the key process parameters and the affected assets, resulting in ineffective asset condition monitoring
- Inability to manage excursion events to maintain the integrity of the assets
- Siloed Inspection data in multiple legacy systems
- Lack of risk-based assessment for inspection intervention determination
- Unstructured inspection reports limiting inspection history analysis
- Limitations in visualizing thickness monitoring data and corrosion rates
- Inconsistent assessment of the assets critically considering integrity standards
The Solution
Bapco Refining’s APM journey started in 2005, as the first APM implementation in the Middle East. At that time the implementation involved a high level of customization to suit the requirements of the Bapco Refining’s Computerized Maintenance Management System (CMMS). In 2018, Bapco Refining upgraded from GE Vernova’s APM version 3.2 to 3.6. However, with this upgrade the customizations were limiting the adoption and utilization of an APM integrated work process. In 2020, an initiative to create a Centralized Reliability Information System defined the path to once again upgrade APM to version 4.6 to remain current and move towards a more composable system limiting the number of customizations impacting the end-to-end workflow.
Bapco Refining nominated a group of leaders and users together with SMEs from GE Vernova’s Power and Energy Resources Software business and worked closely to define APM adoption gaps and the path for the streamlined solution implementation. In early 2023 the implementation of v4.6 was completed, and an adoption plan was put into place.
As part of the upgrade to APM v4.6, Bapco Refining effectively modernized their APM, which included beneficial functionality additions to:
Bapco Refining nominated a group of leaders and users together with SMEs from GE Vernova’s Power and Energy Resources Software business and worked closely to define APM adoption gaps and the path for the streamlined solution implementation. In early 2023 the implementation of v4.6 was completed, and an adoption plan was put into place.
As part of the upgrade to APM v4.6, Bapco Refining effectively modernized their APM, which included beneficial functionality additions to:
- APM Health
- APM Reliability
- APM Integrity
- Policy Designer
- Process Historian Integration
During the upgrade project, the team developed an interface with the existing CMMS based on with GE Vernova’s Automated Data Loaders in APM.
The successful upgrade on the APM system was an important step for Bapco Refining’s enablement of the Centralized Reliability Information System.
The successful upgrade on the APM system was an important step for Bapco Refining’s enablement of the Centralized Reliability Information System.
The Result
Bapco Refining utilized GE Vernova’s OT Connect capabilities to bring process and operating parameters from instrumented equipment and link those to respective assets into the APM asset hierarchy, which enabled the monitoring of asset health and Integrated Operating Windows IOWs Integrity Operating Windows (IOWs) allows users to visualize their risk profile incorporating changing process or operating conditions and their effect on potential damage mechanisms.
Utilizing GE Vernova’s OT Connect functionality. Bapco Refining was able to bring process and operating parameters from instrumented equipment into the APM asset hierarchy. This connectivity and data alignment enabled Bapco Refining to use Integrated Operating Windows (IOWs) so that users can visualize risk profiles and incorporate process changes, operating conditions and the potential effect on damage mechanisms.
Bapco Refining’s IOW program started with the implementation of Risked Based Inspection (RBI) methodology for one of the Vacuum Distillation units. However, the identified IOWs were handled in an ad-hoc system used to visualize Critical Process Variables (CPVs) without a direct integration with affected assets.
RBI is designed to manage excursion events, maintain asset integrity, and improve operational safety. Furthermore, automated email alerts and dashboards enabled a more effective monitoring system to identify process safety bad actors and track follow-up activities. After upgrade and delivery of GE Vernova’s APM, the team can now:
Utilizing GE Vernova’s OT Connect functionality. Bapco Refining was able to bring process and operating parameters from instrumented equipment into the APM asset hierarchy. This connectivity and data alignment enabled Bapco Refining to use Integrated Operating Windows (IOWs) so that users can visualize risk profiles and incorporate process changes, operating conditions and the potential effect on damage mechanisms.
Bapco Refining’s IOW program started with the implementation of Risked Based Inspection (RBI) methodology for one of the Vacuum Distillation units. However, the identified IOWs were handled in an ad-hoc system used to visualize Critical Process Variables (CPVs) without a direct integration with affected assets.
RBI is designed to manage excursion events, maintain asset integrity, and improve operational safety. Furthermore, automated email alerts and dashboards enabled a more effective monitoring system to identify process safety bad actors and track follow-up activities. After upgrade and delivery of GE Vernova’s APM, the team can now:
- Manage overall risk profile of equipment by establishing safe operating and process variables limits and improve predictability of potential degradation.
- Adequately assess the credible degradation mechanisms to improve effectiveness of the inspection program.
- Visualize both real-time critical operational data and process variables to improve communication, decision-making, and proactively act towards excursion events.
- Control the degradation rate by changing the established critical operating parameters limits, thereby, increasing overall asset reliability.
This resulted in Bapco Refining being able to:
- Generate 77 Critical Asset Health indicators linked to near-real time process parameters
- Identify 6 Damage mechanisms established by IOWs for Sulfidation, HCL Corrosion, H2S Corrosion and Wet H2S Cracking
- Create 2 specialized policies designed to monitor IOW excursion for susceptible equipment
Optimized Inspection Planning & Scaling the Thickness Monitoring Program
Optimizing inspection plans is one of the key desirable outcomes of a Risk-Based Inspection (RBI) program. Bapco Refining utilized the RBI capabilities in GE Vernova’s APM Integrity application to help mitigate risk and further extend the mandatory inspections period. Some key benefits of the new approach as stated by Bapco Refining included:
Optimizing inspection plans is one of the key desirable outcomes of a Risk-Based Inspection (RBI) program. Bapco Refining utilized the RBI capabilities in GE Vernova’s APM Integrity application to help mitigate risk and further extend the mandatory inspections period. Some key benefits of the new approach as stated by Bapco Refining included:
- Improved resource allocation based on high-risk area
- More efficient inspection scoping for the plant
- Alignment of inspection intervals with turnaround intervals
- Better visibility using the inspection strategies library
- Unification of thickness data for piping systems and equipment into a single platform
- Easier identification of the problematic assets from a thickness monitoring perspective
- Data cleansing process improved through data visualization and bulk review
- Standardization of inspection records by using APM baseline Inspection Checklists & Reports
- Support for the mechanical integrity workflow structure by implementing a systematic approach and improving traceability
The Thickness Monitoring feature in APM Integrity facilitated the integration of thickness data from various legacy systems, including piping and equipment. While a datalogger was developed in-house with support from GE Vernova in v3.6, Bapco Refining adopted GE Vernova’s standard Data Loader templates in v4.6. This milestone marked the inaugural accomplishment in Bapco Refining’s APM adoption plan and Mechanical Integrity program.
Additionally, data migration for bulk RBI analysis and inspection history were efficiently managed with data loaders, providing faster time-to-value. The parallel processing of data using the new data loading process also improved system utilization and user productivity.
Following the upgrade of the system and user onboarding, Bapco Refinery was able to realize concrete benefits from the GE Vernova’s APM solution.
Additionally, data migration for bulk RBI analysis and inspection history were efficiently managed with data loaders, providing faster time-to-value. The parallel processing of data using the new data loading process also improved system utilization and user productivity.
Following the upgrade of the system and user onboarding, Bapco Refinery was able to realize concrete benefits from the GE Vernova’s APM solution.
APM Integrity
+2000
Assets covered
30
Process Units covered
45%
Improvement in Corrosion analysis time efficiency by using APM Thickness Monitoring
+3,106
RBI Components
4,505
Active risk analyses and what-if analyses
1553
Inspection plans based on RBI methodology
+220
Bapco Refining Specialists using
Capability to improve the inspection plan using RBI 580 risk analysis results.
As a result of the utilizing the RBI-580 Module in one of the main Crude Distillation units, Bapco Refining has been able to identify a risk map of the fixed equipment within the unit. This led to a more efficient inspection plan by allocating the resources and tailoring the inspection scope according to the risk level.
RBI results unlock opportunities to improve process safety performance.
RBI adoption led to the identification of a pressure vessel that was not originally identified with other high-risk equipment. By adopting RBI 580, the analysis showed that the vessel fell under the high-risk category from both a safety and production perspective due to a highly toxic consequence. An inspection plan was elaborated to mitigate the newly assessed risk.
What-if analysis allowed optimizing inspection intervals, efficient risk mitigation and reduced costs
By adopting RBI, Bapco Refining was able to evaluate the effectiveness of the risk mitigation actions in a structured and data-driven manner. Analyzing data from overhead condensers that had a history of costly modification, the What-if Analysis feature allowed Bapco Refining to demonstrate how a metallurgical upgrade would result in a reduction of the risk level and potentially cost reduction.
Improved effectiveness, efficiency, and data quality of the corrosion monitoring program
Through the adoption of the Thickness Monitoring module in APM Integrity, Bapco Refining implemented 8,745 thickness monitoring location (TML) groups with 645,513 thickness measurement locations (TML) for over 2,000 critical assets in the plant. Visualization capabilities in the Thickness Monitoring module enabled Bapco Refining to identify most critical TMLs and also eliminate TMLs that were no longer relevant. There was a substantial increase (approximately 45%) in engineering productivity by reducing the time required to access asset thickness data and analysis.
Increasing awareness and adoption of APM
The awareness program for APM modules and features has been crucial for achieving the RBI implementation results in a short period. Bapco Refining’s leadership enabled an efficient and focused onboarding of the user of the system, which led to shorter time to value.
As a result of the utilizing the RBI-580 Module in one of the main Crude Distillation units, Bapco Refining has been able to identify a risk map of the fixed equipment within the unit. This led to a more efficient inspection plan by allocating the resources and tailoring the inspection scope according to the risk level.
RBI results unlock opportunities to improve process safety performance.
RBI adoption led to the identification of a pressure vessel that was not originally identified with other high-risk equipment. By adopting RBI 580, the analysis showed that the vessel fell under the high-risk category from both a safety and production perspective due to a highly toxic consequence. An inspection plan was elaborated to mitigate the newly assessed risk.
What-if analysis allowed optimizing inspection intervals, efficient risk mitigation and reduced costs
By adopting RBI, Bapco Refining was able to evaluate the effectiveness of the risk mitigation actions in a structured and data-driven manner. Analyzing data from overhead condensers that had a history of costly modification, the What-if Analysis feature allowed Bapco Refining to demonstrate how a metallurgical upgrade would result in a reduction of the risk level and potentially cost reduction.
Improved effectiveness, efficiency, and data quality of the corrosion monitoring program
Through the adoption of the Thickness Monitoring module in APM Integrity, Bapco Refining implemented 8,745 thickness monitoring location (TML) groups with 645,513 thickness measurement locations (TML) for over 2,000 critical assets in the plant. Visualization capabilities in the Thickness Monitoring module enabled Bapco Refining to identify most critical TMLs and also eliminate TMLs that were no longer relevant. There was a substantial increase (approximately 45%) in engineering productivity by reducing the time required to access asset thickness data and analysis.
Increasing awareness and adoption of APM
The awareness program for APM modules and features has been crucial for achieving the RBI implementation results in a short period. Bapco Refining’s leadership enabled an efficient and focused onboarding of the user of the system, which led to shorter time to value.
What’s Next
GE Vernova APM has unlocked numerous opportunities to improve the overall performance of Mechanical Integrity activities for future consideration:
- Enable UT data logger devices: Improve corrosion data quality and relevance by utilizing UT data logger devices, which further reduces the activity completion time and minimizes human errors.
- Optimize Thickness Measurement Location determination: Comprehensively utilize TML data to optimize inspection locations selection and planning
- Legacy Inspection history migration into APM Inspection Management.
- Enable mobile inspection
- Use Asset Strategy Management to improve the cost / benefit balance in risk mitigation
- Continue APM training / awareness program: Enable a broader team in Bapco Refining to utilize APM work processes.