PLANT INTEGRITY MANAGEMENT · 2016. 2. 12. · renewal policy end of life on an equipment life...
Transcript of PLANT INTEGRITY MANAGEMENT · 2016. 2. 12. · renewal policy end of life on an equipment life...
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PLANT INTEGRITY MANAGEMENT
PRESENTED BY
VIJAY VESVIKAR
NDT Level III, CSWIP 3.1, API 570
MANAGER QA, NPC
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MANAGE
INTEGRITY
RISKS OF
AGING
ASSETS
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INTRODUCTION
INDUSTRY DYNAMICS &
PRESSURES
ELEMENTS OF AN INTEGRITY
MANAGEMENT STRATEGY
ORGANIZATIONAL COMPETENCE
ASSET LIFE CYCLE APPROACH TO
ASSET & INTEGRITY MANAGEMENT
CASE STUDY – PIPEWORK
CONCLUSION
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HOW TO MAINTAIN
PRODUCTION CAPABILITY
IN A COST-EFFECTIVE
WAY WHILE PRESERVING
THE INTEGRITY OF
THOSE ASSETS ?
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DEVELOP & IMPLEMENT
AN EFFECTIVE ASSET
INTEGRITY
MANAGEMENT
APPROACH
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INDUSTRY
DYNAMICS &
PRESSURES
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ECONOMIC DOWNTURN
EXTENDED LIFE BEYOND
ORIGINAL DESIGN LIFE
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Initiatives to Gauge Life
Extension of an Asset :
Criticality Assessment
Risk Based Inspection ( RBI )
Reliability Centered Maintenance
( RCM )
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FACTORS COMPROMISING
INTEGRITY OF AN ASSET
MODIFICATIONS
OPERATING EXCURSIONS OUTSIDE
OF OPERATING ENVELOPE
STRESSES EXCEEDING FATIGUE
DESIGN LIFE
OPERATING FOR LONGER PERIODS
THAN ASSUMED
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SAFETY
INTEGRITY
RELIABILITY
RISK MANAGEMENT
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DEVELOPMENT OF PROGRAM
SAFETY
HEALTH
ENVIRONMENT IMPACT
PRODUCTION LOSS
PEDIGREE OF THE ASSETS
UPGRADATION PLAN
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Main Elements of an
Integrity Management
Review
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1. Reliability & Integrity of the
Assets Themselves
2. Effectiveness of the Systems &
Procedures in place
3. Knowledge & Competence of the
Workforce
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HUMAN FACTORS
MANAGEMENT UNDERSTANDING
AND SUPPORT
COMMUNICATION ACROSS THE
LIFECYCLE
EFFECTIVE COMMUNICATION
SYSTEM
DESIGN & CONSTRUCTION
FEATURES
DEGRADATION MECHANISM
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ELEMENTS OF AN
ASSET INTEGRITY
MANAGEMENT
STRATEGY
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ASSET STRATEGY MUST
DEFINE THE
REQUIREMENTS TO BE
PLACED ON THE ASSETS
TO SUPPORT BUSINESS
STRATEGY
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POLICIES :
SAFETY
MAINTENANCE
INSPECTION
RENEWAL
COMPETENCE
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SAFETY POLICY
HAZARDS
MEASURES
PROCESS
RESIDUAL RISKS
OPERATING LIMITS
EXCURSIONS
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MAINTENANCE POLICY
SAFETY & HEALTH
ENVIRONMENT
PRODUCTION
OPTIMUM BALANCE FOR
MAINTENANCE
FITNESS FOR PURPOSE &
INTEGRITY FOR OPERATIONS
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INSPECTION POLICY
TYPE OF EQUIPMENT
SPECIFIC AREA
TYPE OF INSPECTION
TECHNIQUES
FREQUENCY
DOCUMENTATION
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RENEWAL POLICY
END OF LIFE ON AN EQUIPMENT
LIFE LIMITING DETERIORATION
MECHANISM
OBSOLESCENCE
LIFE EXTENSION
SIGNIFICANT REPAIR
MAINTENANCE & INSPECTION
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COMPETENCE POLICY
CORE COMPETENCE
BASICS OF CORE COMPETENCY
EXTERNAL RESOURCES
STRENGTHENING MECHANISMS
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ORGANIZATIONAL
COMPETENCE
COMPETENCE
COMMITMENT
COMMUNICATION
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INFORMATION & DATA
INFORMATION CONTROL
COMMUNICATION ACROSS
CLEAR & CONSCISE INFORMATION
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BENEFITS
INCREASED EQUIPMENT
AVAILABILITY
INCREASED OUTPUT
IMPROVED SAFETY &
ENVIRONMENTAL PERFORMANCE
OPTIMIZED MAINTENANCE COST
STATUTORY & REGULATORY
COMPLIANCE
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CASE STUDY
PIPEWORK IN THE OIL & GAS
INDUSTRY
NOT AN INTEGRAL PART
INADEQUATE ATTENTION
NEGLECTED BY OPERATION,
MAINTENANCE & INSPECTION
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LIFECYCLE OF PIPEWORK
FRAGMENTED APPROACH :
DIFFERENT GROUPS
PLANT TEAMS
SUPPLIERS
CONTRACTORS
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FINDINGS OF HEALTH &
SAFETY EXECUTIVE
CUMMULATIVE EFFECT OF
COMPROMISES IN :
DESIGN
CONSTRUCTION
OPERATION
MAINTENANCE
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ENSURE CO-ORDINATION
IDENTIFICATION
IMPLEMENTATION
SHARING EXPERIENCE
FRESH INITIATIVE
VULNERABILITY
DEFINE PRIORITY
INVESTMENT
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QUESTIONS...
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THANK YOU
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