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Kochi Refinery, a unit of Bharat Petroleum Corporation Limited, is one of two Refineries of BPCL, with a crude oil refining capacity of 7.5 Million Metric Tons per Annum (MMTPA). Now poised for enhancement to 9.5 MMTPA, the product portfolio of the refinery includes petrochemicals and specialty solvents in addition to its range of quality fuels.
Challenges
At the BPCL Kochi Refinery, inspection data was routinely collected by highly trained inspection personnel. However, once collected, this valuable data remained largely isolated, stripping it of its value to identify and track asset improvement opportunities.
Why?
Recognizing the lost opportunities associated with the failure to integrate important inspection data into SAP-PM, the Kochi Refinery launched a new inspection initiative to support a key BPCL business driver - increasing the operational margin of its multiple refineries. The new initiative, Asset Integrity Management System (AIMS), is being rolled out in two phases. Phase I began with the implementation of Meridium Inspection Management (IM) interfaced to the Kochi Refinery SAP-PM system.
Solution
The Meridium IM implementation has moved the Kochi Refinery from a narrow, project-based view of performing inspections, to a broad, asset-based view of not simply performing inspections, but also managing the inspection process through: - Visual inspection planning and scheduling
- Recommendations management
- User-definable inspection workflow
- Equipment inspection profiles
- Inspection alerts
- Roles/task assignments
- Inspector qualification documentation
- Inspection reports
Results
Phase I has enabled the Kochi Refinery to: - Permanently capture the inspection expertise of its workforce
- Document asset condition
- Track inspection recommendations to closure
- Manage inspection plans
- Extract more value from their current inspection efforts and EAM system
Phase II of AIMS will include the implementation of Meridium Risk Based Inspection (RBI).
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