Aim -Methodologies Presentation at Glo - October 2005

7/28/2019 Aim -Methodologies Presentation at Glo - October 2005

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GALIOM

Risk Based I nspection & Asset I ntegrity Management

What is Risk Based Insp ect ion

Risk Based Inspection (RBI) is a method for using Risk as a basis for

prioritizing and managing the efforts of an inspection program.

Why Use Risk Based Insp ect ion

In Operating Facilities, a relatively large percentage of the risk is

associated with only a small percentage of the equipment.

RBI focuses inspection & maintenance resources on the Higher Riskitems and an appropriate reduced effort on Lower Risk items.

What Benefi t in Using RBI

The benefit of an RBI program is to maximize Facility operating run

lengths whilst improving, or at least maintaining, the same level of risk.

What is the Purpose of RBI

Estimate a risk value associated with the operation of each item in a

Process Facility based on a consistent methodology

Prioritize items based on the measured risk.

Design an appropriate inspection program.



GALIOM


G ALI O M Risk Based Inspect ion Methodolo gy

Register Company

Register Location

Register Facility

Register Functional Groups

Register Equipment

Register Features

Record Mechanical Design Data

Record Process Design Data

Determine Failure Mode

Record Failure Mechanism

Determine Theoretical

Deterioration Rate

Determine Remaining Life

Utilize Actual

Deterioration Rate

Determine Consequence

of Failure

Determine Probability of Failure

Determine Risk

Determine Next

Inspection Date

Determine

DeteriorationMonitoring

Locations

Determine Inspection

EffectivenessReference Codes

API 580/581

API 571



GALIOM


What is Asset Integr i ty

Asset Integr i ty is def ined as fol low s:

An asset has integr i ty when i t performs as

specif ied and is being Operated, Inspected and

Maintained as specif ied so that the Risk to People,

Environm ent, Assets and Company Reputat ion

aris ing from i ts fai lure is As Low As Reasonably

Pract icable .



GALIOM


Asset Management

Preventative Maintenance (PM)

Work Scope Preparation

Work Execution

Inspection Report/Memo

Identify Anomaly

Corrective Maintenance (CM)

Asset Data Dictionary RBI - Risk Ranking

Asset Integrity

Status

Follow up actionStatus

Data Analysis

Overdue Status

Highlight Risk

GAL IOM Asset Integr i ty



GALIOM


As set Integr i ty Management Methodo log y

ASRM

(Asset Status Reporting

For Management)

APPLICATION SECURITY

INSPECTION HISTORY DATA

1) Ultrasonic Thickness Data

2) Radiography Data

3) Routine Pigging Data

4) Corrosion Inhibitor Monitoring

5) Cathodic Protection Monitoring

6) Teletest Data

7) SRV Service Records (Condition)

8) ROV Survey Data

9) Pulse Eddy Current

10) General Visual Examinations

TANKS RBI

PIPE RBI

VESSEL RBI

PSV RBI

PIPELINE RBI

TECHNICAL DATA

DESIGN DATA

PROCESS DATA

CMMS MRP SCADA/PI

PROCESS CHANGE

MANAGEMENT

ASSET

REGISTER

Proactive

Action

Required

Alert





GALIOM


G AL I O M Risk Repo rt ing – Risk Matr ix



GALIOM


ASSET INTEGRITY STATUS – Prevent ive Maintenance Overdue

Company Asset Hierarchy screen is color coded to

Highlight Preventative Maintenance Overdue

Immediate Attention - Overdue

Action By Date – within 30 Days

No Action Required



GALIOM


Company Asset Hierarchy screen is color coded to

Highlight Corrective Maintenance Overdue

ASSET INTEGRITY STATUS – Correct ive Maintenance Overdue

Immediate Attention - Overdue

Action By Date – within 30 Days

No Action Required

GA O



GALIOM


Development of GALIOM commenced in June 2004

Initial scope was for Piping, Vessel and Pressure Safety Valves

Initial Development schedule, 1 year to June 2005

Version 0.6 completed in March 2005

Version 1.0 completed in April

First project usage – GUPCO, Egypt in May 2005

Second project usage – PEMEX, Mexico in June 2005 Development & Implementation Team – Mathews Varkey and

Gareth Thomas

G ALI O M – Developm ent History

GALIOM



GALIOM


GLO AIM Group is currently involved in 3 major projects.

GUPCO/BP, Egypt – Currently Facilities include 9 Complexes and

approximately 100 Satellite Platforms. Latest information is that

Lloyds Register will be leaving the Rehabilitation Project by mid

October, 2005 resulting in GLO Egypt receiving another 1

Complex, all remaining Risers and all Onshore facilities.

PEMEX, Mexico – Currently Facilities, Reynosa and Matapionche.

Client comment during meeting September 26, 2005 “Want to

make GALIOM a Best practice within PEMEX”. To this end PEMEX

Gas is considering giving GLO Mexico total of 15 facilities

including facilities already assessed by COMIMSA. Murphy Oil, Malaysia – Three Platforms and interconnecting

Pipelines. Project start October 1, 2005 till December 2005.

G ALI O M – Project Implementat ion Histo ry

GALIOM



GALIOM


No application module development has been carried outsince May 2005

A Pipeline module is required for the Murphy Project inMalaysia. Needs to be completed prior to Mid November

A Structural module needs to be completed for GUPCO, Egyptat the earliest opportunity

A Boiler module needs to be completed for potential work inMalaysia

Remaining required modules are:

Risk Based Maintenance for Rotating Equipment Risk Based Maintenance Module for Electrical and Instrumentation

Storage Tanks

ALARP/MOC/CBA

Development Status

GALIOM



GALIOM


Lack of Personnel – 3 major projects in progress, only 2 staff

to implement, train, monitor and demonstrate application.

Lack of Experience of Assigned Personnel –

GUPCO has Qualified, Certified and Experienced personnel,

mostly Contract PEMEX project is attempting to perform the work with local staff

that is neither trained in RBI or experienced in Facility

Operations, Maintenance or Inspection. This will in the near future

lead to problems with the client

Murphy Oil project will be monitored by the AIM Group in Kuala

Lumpur. Competency of personnel being upgraded with API

Certification, due in December, and the employment of an

experience Operating Plant Inspector from Shell Malaysia Port

Dixon Refinery

Current Problems

GALIOM



GALIOM


A minimum of 5 programmers are required immediately (3

Powerbuilder and 2, .net). Advertisement and Interviews

conducted for these positions. Out of approximately 20

candidates only one considered acceptable.

Corrosion Engineer – To be based in KL. Will work ondeveloping the Failure Mode logics and reference data

Pipeline Engineer – To be based in KL. Will work on

developing the Pipeline RBI/AIM Module

Rotating Equipment Engineer – To be based in KL. Will workon developing the Risk Based Maintenance module for

Rotating Equipment

Immediate GLO A IM Staff ing Requirements

GALIOM



GALIOM


Two servers are required by the GLO AIM Group in KualaLumpur. One a Database server for back up copies of the installed

applications and for the development Databases.

The Second being a Web Server for the development of the .netapplication and remote access

Total Cost estimated RM 20,000

Laptop computers for the Pipeline Engineer, CorrosionEngineer and the Rotating Equipment Engineer.


Oracle database software for application development as

required by clients.Total Cost estimated RM Unknown at present

Other software application to view drawings, compile reportsand assist with logic preparation and Manual writing.


GLO AIM Hardw are and Software Requirements

GALIOM



GALIOM


Programming

Because of the difficulty of obtaining experienced Powerbuilder

and .Net programmers within Malaysia, it is proposed to contract

out parts of the programming to a “Software Development

Company”. For cost and communications reasons it is

considered that India would be preferred area. Mathews Varkey toreview and shortlist potential developers and write proposal.

Deadline December 2005

Module Development

There exists a possibility of forming a partnership with a

Specialist NDE Company that has an API reviewed Tank module.Same Company also has specialist resources for Structural RBI

as Well. Currently using their Certified personnel on the GUPCO

Project

GLO AIM Staff ing Op tion s

GALIOM



GALIOM


Key Focal Point Staff ing

Plant Inspectors

Reliability Engineers

Corrosion Engineers (Not Full Time)

IT/Data Coordinator Specialist

GALIOM



GALIOM

Risk Based I nspection & Asset I ntegrity Management Reliability Engineer

QUALIFICATIONS & EXPERIENCE

B.Sc. in Materials & Corrosion or Mechanical Engineering or an equivalent degree or experience will beconsidered.

Comprehensive knowledge of On-Stream and Off Stream Inspection techniques, specifications and codes

of practice for the inspection of in service oil and gas related equipment.

Comprehensive knowledge of corrosion and maintenance repair techniques of Oil and Gas related

equipment.

Familiar with API 580 and API 581 Risk Based Inspection Recommended Practices.

Knowledge and Experience in the application of API 579 Recommended Practice for Fitness For Service.

At least 5 years experiences in the Oil and Gas industry with at least 2 years experience in an InspectionEngineering role.

Ability to explain Risk Based Inspection and Asset Integrity Management principles is required.

RESPONSIBILITIES

To provide Reliability Engineering support to the Asset Integrity Management Team.

To analyze Inspection data to determine Remaining Life and recommend Inspection and Maintenance

requirements.

To participate in the development of Risk-Based Inspection and Maintenance methodologies.To develop methodologies that assist in the Technical Integrity of Oil and Gas Facilities

Stays current with emerging technologies and Non Destructive Testing-related activities in the Oil and Gas

Industries such as NACE, API, etc.

Compiling and updating Best Practice procedures for analysis of Inspection Anomalies including a

thorough Design review to determine system design parameters and justification for repair.

Carry out "Fitness For Service" analysis of anomalies and make recommendations regarding Repair, Re-

Rate and Replacement Strategies.

GALIOM



GALIOM

Risk Based I nspection & Asset I ntegrity Management Corrosion/Metallurgical Engineer

QUALIFICATIONS & EXPERIENCE

Bachelor of Science Degree in Metallurgical Engineering or Materials Engineering, Mechanical or Chemical Engineering with Metallurgy/Materials emphasis.

Minimum of four years experience in the Oil and Gas Industrial sector.

Self-motivated and strong interpersonal and communication skills required.

Ability to explain materials and corrosion and corrosion control concepts.

Ability to work in a team environment

RESPONSIBILITIES

To provide Metallurgical, Materials and Corrosion Engineering support to the Asset Integrity

Management Team.

To provide Corrosion and Metallurgical expertise in identifying potential Failure Modes and Failure

Mechanisms for the Up-Stream, Mid-Stream and Down-Stream Oil and Gas business sectors.

To participate in the development of Risk-Based Inspection and Maintenance methodologies.

To review Chemical Injection and Cathodic Protection Systems as they relate to Asset Integrity.

Stays current with emerging technologies and materials-related activities in the Oil and Gas Industries

such as NACE, API, etc.

Applies knowledge of engineering principles and practices in broad areas of assignments and relatedfields.

OTHER REQUIREMENTS

Knowledge of Process Safety Management, Plant Operations and Risk experience is desirable.

Knowledge of Computer applications generally used within the Oil and Gas Industry for Corrosion

Monitoring, Risk Based Inspection and Asset Integrity Management.

A “Hands-on” Engineer who has applied him/herself to Oil and Gas Industry Corrosion and Metallurgical

problems is desirable.

GALIOM



GALIOM


Plant Inspector

API 510 &/or API 570 Certification (API 653 as Required)

or

CSWIP Level 1 (preferably Level 2/3)

&

5 years experience In-Service & Shutdown Inspections of

Pressure Equipment

Proposed Progression

Reliability Engineer

As Plant Inspector with:

API 581, Risk Based Inspection 3 or 5 Day CourseAPI 579, Fitness for Purpose Course

2 years experience in an Inspection Engineering role

GALIOM Training – 1 month application familiarization

Documents

Aim -Methodologies Presentation at Glo - October 2005