Risk Based Inspection in the Oil and Gas Industry

Transcription

1 Risk Based Inspection in the Oil and Gas Industry

2 Speaker s Experience in Oil and Gas

3 U.S Coast Guard Marine Inspector Retired From U.S. Coast Guard 1997 last 6 years of which were inspecting Mobile Operated Drilling Ships (MODU) In GoM.

4 Northern Border Pipeline Chicago Project

5 EE&CC Lessons Learned

6 Down Hole Tools

7 FPSO

8 Heavy Weather Drill Ship.

9 Total Quality Management - Oil Tankers

10 Subsea Tiebacks

11 LNG Plant FEED

12 Marine Well Containment System

13 Subsea Equipment

14 Inspection There are a lot of reasons to inspect the things you are buying, making, or going to use. How do you decide which things to inspect given a limited budget? Note: ISO9001:2015 requires risk based thinking across the entire QMS.

15 ISO 3100 ISO risk management principles, risk management framework, and risk management process are the preferred tools to use with ISO management systems ISO has the critical elements of a risk framework, including a focus on culture, risk philosophy, risk definitions, common risk approach, common risk processes, defined roles and responsibilities, importance of accountability, risk competencies, and organizational risk appetite.

16 Risk Based Inspection (RBI) RBI focuses on the optimization of inspection programs. RBI begins with the recognition that the essential goal of inspection is to prevent incidents that negatively impact safety, quality, schedule, and/or cost to the project. RBI first evaluates the consequences and likelihood of system/equipment failure and develops inspection approaches that will effectively reduce the associated risk of failure. RBI is a process that assures inspection resources are focused on the areas of higher risk by assessing consequence of and likelihood of a failure.

17 Consequence Safety Environment Schedule Cost Reputation Difficulty to repair Loss of Traceability

18 Likelihood Past failure rate (review of nonconformities on same part number, by same manufacturer or facility.) Maturity of design (new or has been used for a long time) Number of units being made (more units raise likelihood of one of them failing inspection) Difficultly to find defect.

19 Risk Associated with Inspections

20 Matrix Approach C o n s e q u e n c e Low Medium High Likelihood

21 Score Card Approach PERSONNEL SAFETY - EFFECT ON FAILURE None 1 Possible minor injury 2 Possible major injury / fatality 3 Possible multiple major injury / fatalities 4 HAZARD TO THE ENVIRONMENT EFFECT ON FAILURE None 1 Minimal 2 Moderate with non-lasting effects 3 Major spill with long term effects 4 THE EFFECT OF FAILURE ON PRODUCTION None 1 Minimal 2 Partial Reduction 3 Complete Loss 4

22 Score Card Approach STANDBY AVAILABILITY FAILURE WOULD : Allow use of installed bypass or change out without difficulty 1 Cause operational limitations but with no loss of integrity 2 Allow bypass or change out but with loss of integrity 3 Jeopardize plant operation and has serious consequences 4 FINANCIAL CONSEQUENCES Negligible cost (direct or consequential) 1 Small total cost both direct and consequential 2 Large total cost direct or consequential 3 Large total cost both direct and consequential 4 FLUID Innocuous 1 Non-hazardous, low temperature/pressure/corrosive 2 Hazardous, medium temperature/pressure/corrosive 3 Extreme hazardous, high temperature/pressure/corrosive 4

23 Score Card Approach DESIGN MATURITY Proven design availability 1 Combination of proven design elements for same application 2 Modification of proven design for a different application 3 New, innovative design 4 MANUFACTURING COMPLEXITY Few simple processes 1 Simple processes but more in number 2 At least one complex process 3 Large number of complex processes 4 COMPLEXITY OF MAINTENANCE AFTER FAILURE Single simple operation 1 Routine procedure 2 Complex procedure 3 Highly complex procedure 4

24 Score Card Approach MATERIAL TRACEABILITY No material certificates or statement of requirements required 1 Statement of requirements required 2 Material traceability to origin & shall be capable of correlation to test results 3 Material traceability to origin & shall be capable of correlation to test results & may include full traceability to locations on as-built drawings 4 SCORING Quality is vital and must not be compromised Level Quality is of significant importance Level Quality is of moderate importance Level Normal commercial quality is acceptable Level 4

25 Inspection Levels The setting of inspection levels within RBI is not a rigid process with fixed, predetermined inspection levels. There is, nonetheless, a general logic to the inspections and frequency of the inspections, namely: Higher risk systems/components generally require more inspections. Lower risk systems/components have reduced inspection requirements

26 INSPECTION TEST PLAN An Inspection & Test Plan is a basis for verifying conformity with specified contractual requirements. Customer and the Supplier establish and agree upon the following prior to production start; Inspection Points for the Supplier, Customer and/or Third Party Inspection procedure to be used Notification that good or service is ready for inspection Witness, Hold, Monitor, Review Documentation

27 Level 1 Inspection Inspection Level 1: Full activity surveillance will be required from commencement of manufacture to final acceptance. Inspection activities will be based on an approved Inspection and Test Plan. The ITP will be reviewed and confirmed at a required preproduction meeting. This level is appropriate for Inspection of high risk goods and services.

28 Level 2 Inspection Periodic surveillance activities based on hold/witness/review stages will be required as specified in the approved ITP. The ITP will be reviewed and confirmed at a required pre-production meeting. This level is appropriate for medium risk goods and services

29 Level 3 Inspection Limited surveillance activities based on hold/witness/review stages will be required as specified in the ITP. The ITP will be reviewed and confirmed at a required preinspection meeting. This level is appropriate for inspection of low risk goods and services

30 Level 4 Inspection Final inspection prior to shipment may be required. An ITP and pre-inspection meeting will not be required. This level is appropriate for inspection of goods and services where there is little risk associated with the good or service but where packaging and material traceability affects usability of good at receipt or acceptance of service completion is required

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32 John Gore Contact Info Ride On! Cell: Linked In