PLANT INTEGRITY MANAGEMENT - Nondestructive · PDF fileplant integrity management presented by...
Transcript of PLANT INTEGRITY MANAGEMENT - Nondestructive · PDF fileplant integrity management presented by...
PLANT INTEGRITY MANAGEMENT
PRESENTED BY
VIJAY VESVIKAR
NDT Level III, CSWIP 3.1, API 570
MANAGER QA, NPC
INTRODUCTION
INDUSTRY DYNAMICS &
PRESSURES
ELEMENTS OF AN INTEGRITY
MANAGEMENT STRATEGY
ORGANIZATIONAL COMPETENCE
ASSET LIFE CYCLE APPROACH TO
ASSET & INTEGRITY MANAGEMENT
CASE STUDY – PIPEWORK
CONCLUSION
HOW TO MAINTAIN
PRODUCTION CAPABILITY
IN A COST-EFFECTIVE
WAY WHILE PRESERVING
THE INTEGRITY OF
THOSE ASSETS ?
Initiatives to Gauge Life
Extension of an Asset :
Criticality Assessment
Risk Based Inspection ( RBI )
Reliability Centered Maintenance
( RCM )
FACTORS COMPROMISING
INTEGRITY OF AN ASSET
MODIFICATIONS
OPERATING EXCURSIONS OUTSIDE
OF OPERATING ENVELOPE
STRESSES EXCEEDING FATIGUE
DESIGN LIFE
OPERATING FOR LONGER PERIODS
THAN ASSUMED
DEVELOPMENT OF PROGRAM
SAFETY
HEALTH
ENVIRONMENT IMPACT
PRODUCTION LOSS
PEDIGREE OF THE ASSETS
UPGRADATION PLAN
1. Reliability & Integrity of the
Assets Themselves
2. Effectiveness of the Systems &
Procedures in place
3. Knowledge & Competence of the
Workforce
HUMAN FACTORS
MANAGEMENT UNDERSTANDING
AND SUPPORT
COMMUNICATION ACROSS THE
LIFECYCLE
EFFECTIVE COMMUNICATION
SYSTEM
DESIGN & CONSTRUCTION
FEATURES
DEGRADATION MECHANISM
MAINTENANCE POLICY
SAFETY & HEALTH
ENVIRONMENT
PRODUCTION
OPTIMUM BALANCE FOR
MAINTENANCE
FITNESS FOR PURPOSE &
INTEGRITY FOR OPERATIONS
INSPECTION POLICY
TYPE OF EQUIPMENT
SPECIFIC AREA
TYPE OF INSPECTION
TECHNIQUES
FREQUENCY
DOCUMENTATION
RENEWAL POLICY
END OF LIFE ON AN EQUIPMENT
LIFE LIMITING DETERIORATION
MECHANISM
OBSOLESCENCE
LIFE EXTENSION
SIGNIFICANT REPAIR
MAINTENANCE & INSPECTION
COMPETENCE POLICY
CORE COMPETENCE
BASICS OF CORE COMPETENCY
EXTERNAL RESOURCES
STRENGTHENING MECHANISMS
BENEFITS
INCREASED EQUIPMENT
AVAILABILITY
INCREASED OUTPUT
IMPROVED SAFETY &
ENVIRONMENTAL PERFORMANCE
OPTIMIZED MAINTENANCE COST
STATUTORY & REGULATORY
COMPLIANCE
CASE STUDY
PIPEWORK IN THE OIL & GAS
INDUSTRY
NOT AN INTEGRAL PART
INADEQUATE ATTENTION
NEGLECTED BY OPERATION,
MAINTENANCE & INSPECTION
FINDINGS OF HEALTH &
SAFETY EXECUTIVE
CUMMULATIVE EFFECT OF
COMPROMISES IN :
DESIGN
CONSTRUCTION
OPERATION
MAINTENANCE
ENSURE CO-ORDINATION
IDENTIFICATION
IMPLEMENTATION
SHARING EXPERIENCE
FRESH INITIATIVE
VULNERABILITY
DEFINE PRIORITY
INVESTMENT