Surface Operations Integrity Management. Bucharest March 13 th 2012

Transcription

1 Surface Operations Integrity Management Bucharest March 13 th 2012

2 OMV Petrom Group, the largest oil and gas producer in SEE Exploration and Production Romania and Kazakhstan mn boe total hydrocarbon production 5.32 bcm Group gas production 812 mn boe Group proved reserves Refining and Marketing Upstream integrated refining capacity ~800 filling stations at Petrom Group level 4.07 mn t Petrom Group marketing sales Gas and Power 5.05 bcm Group gas sales Strong position on the Romanian gas market, covering all gas market segments 860 MW Brazi power plant to start commercial operations in H2/2012 All figures as of December 2011; figures refer to Petrom Group 2 Integrated Asset Integrity Management

3 Exploration and Production Facts and figures Romania Proved reserves at end of 2011 in Romania: 786 mn boe Reserves replacement rate in 2011: 70% Crude oil and NGL production in 2011: mn bbl Kazakhstan Proved reserves at end of 2011: 26 mn boe Crude oil and gas production: 4.36 mn boe 3 Integrated Asset Integrity Management

4 Definition of ASSET INTEGRITY from OGP Asset integrity is related to the prevention of major incidents. It is an outcome of good design, construction and operating practices. It is achieved when facilities are structurally and mechanically sound and perform the processes and produce the products for which they were designed. The emphasis is on preventing unplanned hydrocarbon releases that may, either directly or via escalation, results in a major incident. 4 Integrated Asset Integrity Management

5 Emphasis on Process Safety Process Safety is a disciplined framework for managing the integrity of hazardous operating systems and processes by applying good design principles, engineering and operating practices. It deals with the prevention and control of incidents that have the potential to release hazardous materials or energy. Such incidents can cause toxic effects, fire or explosion and could ultimately result in loss of life, serious injuries, property damage, environmental impact and lost production 5 Integrated Asset Integrity Management

6 Relationship Asset Integrity & Process Safety Owned & Assured by HSSE AIM PSM System 6 Integrated Asset Integrity Management

7 Integrity Program Integrity Program to bring facilities up to compliance with regulatory requirements in terms of Legal requirements Environmental requirements Technical condition Safety Prioritization done based on risk assessment and existing condition assessments 7 Integrated Asset Integrity Management

8 Integrity Program 8 Integrated Asset Integrity Management

9 Integrity Management Program Pipelines ESD&Fire&Gas Detection Replace Boldesti De Gasolinization facility with LTS MIRD Program-Fix Derricks H2S and CO2 (detection, escape eqpt. & training of operators) Gas conditioning Process Safety (PSV s, Pipework and Venting) Tanks / Habas Integrity Management Program includes 14 work streams Boilers & Heaters Inlet Manifolds, Piping's, Valves Electrical network power system Wellhead X-mas Trees - New Roads Integrity Technical Documentation 9 Integrated Asset Integrity Management

10 Asset Integrity Management Pillars Asset Integrity Surface Facilities and Pipelines Information and Processes Organization Risk Based Approach to 2012 High risk facilities (14 work streams, 25 M Euro) - Mgt of high risk facilities against Earthquake and Flood - Critical Infrastructure program RBI (Static Equipment) and PIMS - Pilot Study Asset 2 High Risk Gas asset - Roll out to all Assets Pipeline Prioritization Project for repair and replacement - Risk Rank High Risk Facilities Engineering and Design - Process Safety standard incorporated in design phase Inspection and Maintenance - Maintenance Strategy Review Corrosion management - Corrosion Inhibition Program wells Facility Abandonment - Pipeline Abandonment Program new PI department Technical Documentation - Document Mapping: Identify & develop all Operational Doc. in HQ, Assets and Projects MOC - Eng Change Proced. developed and process in function Permit To Work - Pilot e Permit System Asset X Operational Readiness Assurance - Dedicated resource to all new projects Process Safety - Safety Critical Elements identified - Perform Stand Brown & Greenfield sites - SAP align, custom FL and WO screens - PS MWA & KPI s IT System & Data Management - epermit - SCE Database - RBI and PIMS Software - SAP Data Integrity gap analysis Audit - PS and SCE Audit Organization - Dedicated PIM Team set up in HQ - Pipeline & Static Equipment RBI teams in Assets - Dedicated PS Resource per asset Accountabilities - New JD s and R&R for new teams in HQ and Assets - Redefine Operator R&R and first line maintenance Training and Competency - JD redefined for new organization - Training and Competency Matrix to be developed - Gap Analysis and program establish - RBI Training (Methodology and Software) - Bowtie Risk assessment training complete 10 Integrated Asset Integrity Management

11 Safety Critical Elements Safety Critical Element (SCE) - Any part of the facilities (including software) the failure of which could cause or contribute substantially to a major accident, or the purpose of which is to prevent or limit the effects of a major accident. Guideline for Identifying Safety Critical Elements - EP-HQ-03-GL-008-OO 11 Integrated Asset Integrity Management

12 Process Safety Management Plan Greenfield (Hurezani & Midia) Safety critical elements are normally identified as a result of a safety case and hazard register development during the design stage Risk Assessment Safety Case Major Accident Hazard focused risk assessment report identifies MAH Act on outcomes and update Barriers Performance Standards Verify Performance Hazard Register describes barriers and SCE are defined. Performance Standards developed and Safety Critical Equipment are identified in maintenance system. Written Scheme of Verification created and Inspections & maintenance conducted Issues register is generated 12 Integrated Asset Integrity Management

13 BOW Tie: Hydrocarbon Containment 13 Integrated Asset Integrity Management

14 Process Safety Management Plan Brownfield Where a formal risk assessment is not available to identify safety critical elements an alternative approach is required OMV SCE Guidelines OMV SCE Guideline EP-HQ-03-GL for Facilities where no HSE Case exists Act on outcomes and update Generic Barriers & Analysis Generic Performance Standards Verify Performance SCE are defined using flowchart for identifying safety critical elements Generic Performance Standards developed and Safety Critical Equipment are identified in maintenance system. Written Scheme of Verification created and Inspections & maintenance conducted Issues register is generated 14 Integrated Asset Integrity Management

15 Flowchart for Identifying Brownfield SCEs Guideline for Identifying Safety Critical Elements EP-HQ-03-GL Integrated Asset Integrity Management

16 SAP record for Functional Location 16 Integrated Asset Integrity Management

17 Start up and Year 1 management is crucial for a successful program lifecycle SOI department in 2012 is responsible for management, control and execution of a high number of integrity projects with significant impact on Petrom E&P, Operations, HSSE and process safety. Different scopes of work with need for alignment & interdependency management between subprojects & work streams Need for interaction and coordination with other departments High visibility and delivery to Senior Management (significant budget allocation ) Need for audit proof management processes (incl. documentation) Expansion of SOI department scope and project landscape Pipeline Integrity Team Petrom Risk Management (Floods & Earthquakes) Critical infrastructure Inclusion of all Pipeline and Roads Projects 2013 Significant risks to be considered and mitigated Current situation / challenges Review and propose Integrity Program for 2013 (budgets, risk workshops, action plan) 17 Integrated Asset Integrity Management

18 Thank You