Module 03 - Working Procedures & Software
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Transcript of Module 03 - Working Procedures & Software
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Working Procedures &Software
RBI Offshore Training Course
Module 3
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Content of the module
This module covers:
• Inspection Management working proceduresand Guidance
• Description of the Synergi RBI Offshore
software• Work flow & use of Synergi RBI Offshore
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Inspection Management Circle & Working Procedures
Acceptance Criteria
Information gathering
& screening
Detailed RBIPoF calculation
CoF Unignited
CoF ignited
Reporting
Inspection programme
Inspection planning
& execution
Data evaluation and Updating
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RBI Team• RBI team must be multidiscipline
• The team should include the Client / operating
unit
• There should be the following disciplines
present:
– Consequence / Risk
– Materials / Corrosion
– Inspection
• The Client/Operating unit should contribute
detailed installation operations and maintenance
knowledge.
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Synergi RBI Offshore
• Determine when to inspect, where to inspect
and how to inspect, or whether monitoring is abetter solution
• Assess how changes in process and materials
affect the installation risk and inspectionprogramme
• Aid to managing installation risk to be within
the Clients own acceptance criteria
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Synergi RBI Offshore: Outputs
• Calculates quantitative values per tag for:
– Risk – PoF
– CoF for Safety, Economy
– Inspection date (≈
Time to risk limit)• Lists likely degradation mechanism
• Can output graphically (matrix) or numerically
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Synergi RBI Offshore: Program features
• Project (data set) administration
• Gridview Spreadsheet-like editing• On-line help
• Development is continuing
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Synergi RBI Offshore: Main Data &
background data• Main data are the corrosion circuit, tag and part, which
contains the tag-specific data with repair method &
process conditions• “Background data” are data used many tags, such as
materials & coatings type and properties, model
properties etc
• Because of the relationships, the background data
should be lset first, then circuit, tag and part last.
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15
Asset Hierarchies in Synergi RBI Offshore
• Asset hierarchies designed to facilitate the analysis
process
RBI Study Node
Field
Installation
System
Tag
Inspection
Part
Inspection
Thickness Measurement Location
Area
Isolatable Section
Tag
Corrosion Circuit
Tag
Corrosion Circuit
Part
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Synergi RBI Offshore: Design philosophy
• Probabilistic modelling
• Fallback system if data is missing, e.g.:Age: 1. Component, 2. System, 3. Installation
Temperature: 1. Actual, 2. Operating, 3. Design
• Calculation reports for documentation of
decisions made during calculations
• Option for manual override of corrosion rate
and PoF
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Synergi RBI Offshore: Limitations
• Many PoF models have been simplified to
reduce data gathering and entry requirements,
but this can still be extensive.
• Remember GIGO: Garbage in, garbage out.
Careful data entry and verification pays.
• Uses a different PoF methodology to Synergi
RBI Onshore - direct calculation of PoF, no use
of generic data.
• Limited to physical processing of hydrocarbons
at low temperatures (< 150C)
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Work flow
• Follows the Inspection Management Circle
• DNV (Offshore RBI) allows a multi-stage work
process :screening then possibly a semi-
quantitative and then fully quantitative RBI:
– Reduces number of tags to be assessed, reducing
data search & handling
– Involves & motivates the Client
– Transfers installation knowledge where documents
do not exist
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© Det Norske Veritas AS. All rights reserved.
Sunday, 08 May 2011
21
Synergi RBI Flexible Workflow Example
Collect relevant
data
Level 1 RBI : Screening At System& Circuit level
Annual GVI . Corrective
maintenance
Inspectionplanning
Inspectionexecution
Assess findings & upadte
database withfindings
Need to Update RBI ?
Level II RBI : Semi - Q
Assessment per circuit Use of DNV RP - G 101
Create Circuits
Low risk
High risk
Medium risk
Low risk
Level III RBI: Detailed
Based on subdividing circuits intotags & subtags Use of ORBIT Offshore
High
risk
Inspectioninterval
acceptable ?
Yes
NoRisk analysis Risk Level
Other riskmitigating actions
Confirm data Unacceptable
risk
Medium risk
Acceptable risk
No
Yes
Risk analysis Risk Level
Risk analysis Risk Level
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Acceptance Criteria determination
• Since inspection time is based on exceeding a
risk limit, we must define those limits
• Screening & detailed RBI need the acceptance
limits
• Specify quantitative limits for safety, economy& environment
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Case Study: Veritas 1 Wellhead Installation
• Input:
– P&IDs in Training manual– RBI Study Input Data: Handout “Contract between Operator
AS and RBI Planners AS for Inspection Services on the Veritas
1 Wellhead Installation
Slide 23
Wing Valve ESD
Export Pumps
Condensate/Gas Gas
Condensate Booster Pumps
Water
Separator 20VA0001
MeteringPackage
E x p o r t R i s e r
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Creating a Case study
• Open Synergi RBI Offshore
• File/ Save As “Veritas 1 Case Study.orbx”
under folder C:\trainingFiles
Slide 24
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Name Field and Installation
• Rename to “Veritas Field” and “Veritas 1
Installation”
Slide 25
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Synergi RBI Offshore - Installation
• Used to define general installation details for
CoF calculations• Lists installation name, production volumes &
values, set risk acceptance limits, give
equipment costings (per tonne)
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Exercise: Installation Data
• Fill Installation Dialogue:
– PLL limit: 0.0001– Economic limit: 10000 USD
– Sand present: No
– CO2 present = Yes– Unselect option: Include consequence fatalities in
economic risk
– Production affected (CostPerday)= (Throughput
(bbl/day)* OilPrice($/bbl) ->
$/day=5000*100=500,000 USD/day=150,000,000
USD/year
Slide 27
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Installation
• Double-click on Veritas 1Platform and to enter
data
Slide 28
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CoF Input
Slide 29
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Installation Inspection Targets
Slide 30
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Installation Parameters
• Correct: Oil Throughput 5,000 bbl/day
Slide 31
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Data gathering & Screening - 1
• Request all necessary data up front; specify what
stage of the project it is needed by.
• Preferably get tag data electronically, as it saves
a lot of work & errors are less likely to be your
fault.
• Include Operating unit in the screening - they
must agree the result and often are the main
source of relevant information. Involvement alsogenerates acceptance of the RBI & goodwill.
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Data gathering & Screening - 2
• The purpose of screening:
– Reduces data to be assessed later– Increases our knowledge of the installation
– Gets the Client firmly on the RBI side
• The outputs of screening:– Systems with high PoF and CoF go to detailed RBI
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Data gathering & Screening - 3
Information required for screening is
• PoF:
– Materials,
– product service code & chemical description of content,
– temperatures, pressures,
– coatings, insulation types, current condition, likely changes in
these with time.• CoF:
– How the installation works, inter-relation between systems,
installation layout,
– revenue streams, costs of inspection,– detection and shutdown systems,
– blast & firewalls.
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Data gathering & Screening - 4
• Screening process
– Assess PoF and CoF against conservative acceptancelimits
– High PoF and high CoF: Detailed RBI
– Low PoF and high CoF: Preventative maintenance
– High PoF and low CoF: Corrective maintenance
– Low PoF & low CoF: Minimal surveillance
• Revise the screening periodically, as conditionschange and so may the assessment.
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36
Screening Matrix
A Detailed RBI
B InsignificantPoF
C
I n s i g n
i f i c a n t C o F
D
PoF
1
10-2
10-3
10-4
10-5
Low ― Consequence― High
High PoF
Low PoF
Low CoF High CoF
Minimum
Surveillance
CorrectiveMaintenance
Preventive
Maintenance
Detailed RBI
Assessment
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Screening matrix & reasons for revision
Likelihood of failuremay increase because
of material and
process
changes
A B C D E
Consequence of Failure
L i k e l i h o o d
o f F a i l u r e
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Detailed RBI: Synergi RBI Offshore - System
• Used to describe the process and utility systems
on the installation, and records whether MIChas been identified there.
E i S i A f S
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Exercise: Screening Assessment for System
20: Separation and stabilisation
• Insert System 20 – Separation and Stabilisation (in
Systems folder), Right-click System Screening &fill data
Slide 39
E i S i A t f S t
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Exercise: Screening Assessment for System
20: Separation and stabilisation
• System boundaries: Wing valve, oil, gas and
water outlet isolation valves• Input material, product service, temperatures &
pressures
• Assess PoF and CoF• Click on Run to see the screening results
Slide 40
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System Screening
Slide 41
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Detailed RBI - 1
• Assesses individual tags and parts of tags
• Results in a quantified risk level and time toinspection per tag or part
• Input PoF and CoF data
• Ensure close contact and co-operation withOperating Unit
• Can report any way the inspection planner
wants• It is time and information-intensive
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Detailed RBI - 2
• Work systematically & document all
assumptions
• Enter all the tags otherwise people might think
you forgot some;
– also they might be screened back in in the future.– Mark those screened out in the comment field.
• Assign process conditions and consequences to
tags
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Detailed RBI - 3
• Electronic tag data must specify dimensions,
service, materials, coating, insulation,
temperatures, pressures, P&ID no. as aminimum.
• Reference to drawings is used to assign tags to
ESD Isolatable sections, areas.
• Process conditions assigned according to PFDs
and process simulations
• Repair strategy & production losses assigned
according to client strategy
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Detailed RBI: Handling Piping
• Piping tags may have elbows, straights, tees &
reducers. These separate components are not
usually treated separately for RBI, but may have
different wall thicknesses and diameters.
• Pipe often quoted as a “schedule”.
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Example of pipe tag with tapping
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Detailed RBI: Handling Vessels - 1
• Vessels should be defined as Tags
• Divide them up into their components with the
correct label, dimensions & materials as Parts.– It is conservative to assume the same schedule
for the nozzle as the attached pipe
• Assign each part the appropriate product servicecode
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Detailed RBI: Handling Vessels - 2
• Synergi RBI Offshore is designed for items
with fluid on the inside and atmosphere on the
outside, so heat exchanger tubes are not easily
handled
• Synergi RBI Offshore uses pipe stressequations from ASME/ANSI B31.3 to calculate
stress
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Detailed RBI: Handling Vessels - schematic
PT
PL
PW
Gas
Oil
Water
PG
Closed drains
Two phase
Water
Gas
Oil
Different
codes
Most
conservative
code
Oil
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Detailed RBI: Synergi RBI Offshore - Area
• Used to describe each area/module for risk
calculation
• Lists size, no. of equipment & personnel, factors
affecting likelihood of ignition & spread,
mitigating factors• Use the layout drawings or line list to determine
areas & Isolatable sections
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Exercise: Insert Area
• Right-click on Areas and insert Consequence
Area. Right-click and rename it to Lower Deck
Slide 53
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Exercise: Edit Area Lower Deck
• Double-click on Area and fill data
Slide 54
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Exercise: Area
• Pressure Wall Design Pressure = 1 bar
• Equipment design pressure= 0.3 bar• Maximum Explosion Pressure = 0.5 bar
• Assume that
– half of people in Lower Deck – half of people in Upper Deck
• Input rest of the data, estimating as necessary
from available data (volume, area, ventilationrate etc)
Slide 55
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Area Data
Slide 56
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Detailed RBI: Synergi RBI Offshore - Isolatable section
• Used to specify all the parameters needed to
calculate the simplified RBI-QRA per Isolatable
section for ignited CoF.
• List by Isolatable section the temp, pressure,
volume, area, fluid contents, potential for spread
to areas, equipment & risers
• Is used for detailed analysis
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Exercise: Insert Isolatable Section
• Draw simple PFD/ Define isolat. section bounds
• Right-click on Isolatable sections, Insert
Isolatable section and rename to Separation
Slide 59
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Exercise: Define Separator Isolatable section
• HOLDING POINT
Slide 60
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Exercise: Define Separator Isolatable section
Slide 61
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Exercise: Define Separator Isolatable section
• Calculate RBI QRA = Yes (use Synergi RBI
QRA model rather than external QRA)
• Assign Isolatable section to Lower Deck
• Lower Explosion Limit = 0.01
• Riser Fluid = Oil• Flash Fraction Oil = 0.2
• Kappa Gas = 1.3
• Mass burning rate = 0.05 kg/m2/s
• Molecular weight = 98 (condensate)
Slide 62
I l bl S i D
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Isolatable Section Data
Slide 63
I l t bl S ti D t
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Isolatable Section Data
Slide 64
E i I t C i Ci it
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Exercise: Insert Corrosion Circuit
• Right-click on Corrosion Circuits folder and
insert Corrosion circuit. Rename to separator
corrosion circuit
Slide 66
E i Fill C i Ci it D t
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Exercise: Fill Corrosion Circuit Data
• Double-click on separator corrosion circuit and
fill data under General
Slide 67
Separator Corrosion Circuit data
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Separator Corrosion Circuit data
• Optional exercise: Screening of corrosion circuit
Slide 68
Detailed RBI: Synergi RBI Offshore Tag
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Detailed RBI: Synergi RBI Offshore - Tag
• Can be a vessel, a pipe or a generic tag
• Tags can comprise a number of parts, such as the
individual components of a pressure vessel as shown.
Exercise: Insert Separator Tag
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Exercise: Insert Separator Tag
• Right-click on Separation & Stabilisation
system and insert Vessel-Horizontal Vessel
Slide 70
Exercise: Fill Separator Data
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Exercise: Fill Separator Data
• Right-click on Horizontal Vessel and choose Rename to
change to Separator 20VA0001
• Double-click on Separator 20VA0001and fill
20VA0001 data under General and Design tab• Assign isolatable section and corrosion circuit
Slide 71
Exercise: Fill Separator Data
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Exercise: Fill Separator Data
Slide 72
Separator Tag Data
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Separator Tag Data
• Separator Tag Design Data are inherited from
System. Edit if required
Slide 73
Detailed RBI: Synergi RBI Offshore - Part
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Detailed RBI: Synergi RBI Offshore - Part
• The lowest level of detail in Synergi RBI
Offshore. Used to assign all physical, process
and consequence data to individual parts.
• Makes the links between the background tables
and the results tables.
• Most fields require the background tables to be
completed first, so work on Parts last.
Exercise: Insert Part
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Exercise: Insert Part
• Right-click on Separator 20VA001 and Insert
Part Shell. Rename to Part-Shell-Oil Side
Slide 76
Exercise- Fill Part Data
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Exercise Fill Part Data
• Double click on Shell – Part – Oil side and fill
part data as necessary
Slide 77
Exercise- Fill Part Data
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Exercise Fill Part Data
Slide 78
Exercise- Fill Part Data- Design
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Exercise Fill Part Data Design
• Material can now be specified precisely
Slide 79
Exercise- Fill Part Data - Detailed
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a a a a
• CoF Method can now be quantitative
Slide 80
Exercise- Fill Part Data - Detailed
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• Must specify repair categories and Production
loss profile
Slide 81
Detailed RBI: Synergi RBI Offshore -
ProdLossProfile
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• Used to define the production loss profile resulting from
leak in pressure boundary for economic CoF calculations
• Production Loss profiles are defined in Repository editor
Full production
Time0
100
Detailed RBI: Synergi RBI Offshore –
Repair & Repair Diameter
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• Used in Unignited consequence calculations
• Defines the repair strategies for each part type for
economic CoF calculations
• Repair times are defined in the Repository editor
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Safeguarding life, property
and the environment
www.dnv.com
102