Integrity Management Software Solution Managing your daily activities.

Transcription

1 Integrity Management Software Solution Managing your daily activities. S. Ruik Beyhaut Product Management ROSEN Integrity Solutions GmbH Lingen, Germany

2 Contents Why does the industry need Asset Integrity Management? Why should we maintain our tanks? Maintenance Excellence Develop Inspection Methodology Case Study ROSEN s Tank RBI methodology Conclusion

3 Why does the industry need Asset Integrity Management? To avoid and mitigate against major accidents or incidents, by ensuring major accident barriers are in place and are rigorously maintained. With an ageing asset infrastructure there is a requirement for effective process safety management, and major hazard risk controls to be in place. Washington, 2002 Flixborourgh UK 1974 UK 1988 Mexico 1984 USA 1989 Texas City USA 2005 Alaska Pipeline USA 2006

4 Why should we maintain our tanks? To ensure that physical assets continue to do what their users want them to do (to fulfill their intended functions) Reliability (no major HSE incident) Availability Cost effective (where should we spent the money) Structured working process (auditable) Don t create backlog Cost associated with operating Tanks $ 3 10 M $ M 1. Catastrophic failures (reputation, clean-up) 2. Unplanned shutdowns (non-availability) Avoid (1)(2) $ M 3. Planned shutdowns (cleaning, repair) Optimize (3) $ M 4. In-service maintenance & inspection (NDT) Minimize (4)

5 Four stages to Maintenance Excellence Stage I Fire-fighter Stage II Controller Stage III Innovator Stage IV ME < 30% mhrs spent on PM 30-50% mhrs spent on PM 50-70% mhrs spent on PM > 80% mhrs spent on PM < 80% schedule compliance 80%-90% schedule compliance 90-95% schedule compliance > 95% schedule compliance Failure modes unknown Minimum Risk focus Absence of PM eqpt audits Failure modes inventory PM s viewed as filler work Major pieces of equipment classified and receive PM focus Condition based maintenance techniques Formal PM audits and updates Application of RBI/RCM techniques Focus on failure prevention PM based on failure mode and failure effects Disciplined planning & scheduling Absence of equipment criticality classification No performance measurement Operators & craftsmen jointly responsible for PM Formal KPIs Performance analysis & improvement So we must aim for the best of the best Risk is not gambling Compliance is a key No doubt your performance will fit in different sections HW the aim and direction of focus is clear

6 Cost Effectiveness of Maintenance COST Fire-fighting mode Comfort mode PREVENTIVE MTCE. COSTS COST OF NON- AVAILABILITY PROD. LOSS + BREAKDOWN NOT ENOUGH EFFORT OPTIMUM TOO MUCH EFFORT MAINTENANCE EFFORT

7 Develop Inspection Methodology The inspection methodology or scope should be specific for each tank: Design Product Potential failure mechanisms Integrity Services: 1. Inspection Services 2. Engineering Services 3. Consultancy Services 4. Integrity Management Support Services

8 1. Inspection Services MFL Floor scanning (incl. repair plan) Shell thickness measurements API / EEMUA Inspections / NDT services (MT, PT, UT, LT) 2. Engineering Services Compliance checks (API653 / EEMUA159 / National) Repair advise, detailed eng.. (e.g. modifications, new tank(s)) 3. Consultancy Services Training & Workshops V.O.C. Emission control Development of procedures or guidelines 4. Integrity Management Support Tools for upgrading your Tank Integrity Management System Tank prioritization program (MRP health check ) Asset Management base & Tank RBI (ROAIMS)

9 ROAIMS for Tanks The streamlined software design and its comprehensive database offers a range of user-friendly modules: simplifying data organization and management supporting task planning/scheduling moving from time based to condition based (preventive maintenance) provide tailored reporting capabilities to meet both internal and external requirements.

10 Case Study General Overview ECOPETROL S.A., biggest state-run pipeline operator in Colombia implemented the project The purchase of an IT tool to support & manage Pipeline and Tank Integrity. Implementation & Customization of a Pipeline & Tank Integrity Management Software Risk Assessment of its Pipelines Set up a Risk Based Inspection Plan for its Storage Tanks Software tools for Quality Assurance/Quality Control of the individual processes Centralized database for increasing knowledge about condition and reliability of its assets Overall goal: Supporting tool to develop prioritization and repair plans

11 Project Scope Overview Total Length of pipeline network: 6800 km (different diameters) Total Tanks: 260 spread all over the country Different sizes from 10 mts to 60 mts diameter Mechanical data, tank inspections and other important data were available in printed version and excel sheets. Integration of External Inspection results (CP, DCVG, CIS, Soil Resistivity, ) Consecutive ILI runs available ( 50+ ILI runs, various vendors) Codes, Standards & Legislations HSE Policy Legislative Requirements Integrity Performance Standards Operations Policy Audit & Review

12 Design/Construction Integration of Pipeline, facilities physical properties. Design / Construction Risk Re- Assessment HCA Identification Rehabilitation Action Tracking Asset & Integrity Management Gathering Immediate & Future Repair Prioritization Inspection Integration Risk-based Prioritization

13 Gathering Systematic methodology & storage to support IM process Collection & Integration Alignment > 6800km of pipelines Analysis > 260 Tanks Rehabilitation Action Tracking Risk Re- Assessment Design / Construction Asset & Integrity Management HCA Identification Gathering Immediate & Future Repair Prioritization Inspection Integration Risk-based Prioritization > 8000 documents

14 Risk-based Prioritization Identification & prioritization of risks to determine, how, where and when to allocate mitigation resources Design / Construction Tank Inspection prioritization Risk Re- Assessment HCA Identification Rehabilitation Action Tracking Asset & Integrity Management Gathering Immediate & Future Repair Prioritization Inspection Integration Risk-based Prioritization

15 Risk-based Prioritization (ROSEN s Tank RBI methodology ) Complies with the API requirements for applying RBI Final deliverable is an inspection plan for tank & its sub-components, with details of activities related to the current operation from a S/H/E/E standpoint. For risks considered unacceptable, the plan contains the mitigation actions, scope and timing of inspection/examination recommended. RBI Benefits and Limitations This RBI plans also identify equipment which does not require inspection An important decrease on the amount of inspection data that is collected Rubbish in, is Rubbish out. RBI will not compensate inaccurate or missing information, inadequate designs equipment installation, operating outside acceptable design envelope, not effectively executing the plans in a timely manner, lack of qualified personnel or teamwork, and lack of sound engineering judgment.

16 Project Framework for RBI implementation (Tanks) Approach of Implementation, based on API 580. The core of a RBI assessment: team-based process. Identification of the appropriate deterioration mechanisms, failure modes for all tank components, which had an effect on the quality & effectiveness of the RBI Risk model customized, regional peculiarities ( e.g. Company image/reputation) RBI is a dynamic tool

17 Risk-based Achievements (Tanks) Optimize routine operation on basis of condition Reduce out-of-service time (non-availability cost) Spread maintenance and inspection effort

18 Rehabilitation Action Tracking Follow up of repair actions including resource planning and NDT comparison, GIS update activities Design / Construction Budget planning and track the status of field activities Coordinate tasks on the basis of both risk and maintenance based tasks Rehabilitation Action Tracking Risk Re- Assessment Asset & Integrity Management HCA Identification Gathering Immediate & Future Repair Prioritization Risk-based Prioritization Inspection Integration

19 Conclusion Turn Key Management Solution: Development Phase Acceptance Phase Support

20 Conclusion Overall project implementation : High quality and transparency of information via central database Central Intelligence Center keeps track of actions in branches Permanent Trainings and involvement during project ensures ability to self-operate Delivery is used as master source for future maintenance budget planning After 18 months of intense development, testing and good teamwork the system was implemented at ECOPETROL and the corresponding admin and user training delivered. Overall benefits of Tank RBI implementation : Structured approach of Maintenance & Inspection activities Justification process for preventive Maintenance &Inspection budgeting Loop based process (based on experiences and evidence) Development of proactive Maintenance &Inspection tasks Focus on critical tank (sub-) components Reduce out-of-service period Increase availability & reliability Better scope of work (and $) definition prior O.O.S. (out-of-service) Engineering experience, training, codes and so further, together with a sophisticated software solution are the key to success when comes to implementing an Asset Integrity Management into a Storage Tank Operator.

21 Enjoy the Conference