Risk Based Inspection part of Aker - · PDF fileRisk level / inspection plan OK? Detailed...

part of Aker

© 2011 Aker Solutions

Risk Based InspectionDynamic optimisation of inspection plans

Øystein Bjaanes, Manager AIM Competence Centres

part of Aker

© 2011 Aker Solutions part of AkerFebruary 2011 Slide 2

Content

■ Aker Solutions in brief – Who we are and what we do■ Risk Based Inspection■ Dynamic optimisation of inspection plans / integrated planning■ Non-Intrusive Inspection – a significant contribution to optimisation

part of Aker

© 2011 Aker Solutions

Who we are and what we doAker SolutionsJanuary 2012

part of Aker

© 2011 Aker Solutions part of Aker

In Brief

Slide 4

Aker Solutions in brief

■ A leading global provider of engineering and technology, products and service solutions to the oil and gas industry

■ Employees: 18 000Contract staff: 4 600Operations in 30 countries

Revenues and profits are for 2010 Market value as of 04.11.2011

Operatingrevenues

NOK 33.4 bn

Operatingprofit (EBITDA)

NOK 3.3 bn

Marketcapitalisation

NOK 18.3 bn11th largest

on OBX index

http://www.akersolutions.com/NR/rdonlyres/9F747D0E-B281-43A3-B604-0305DF2EDD00/20975/DES004.jpg�

© 2011 Aker Solutions part of AkerSlide 5

Our vision and valuesBuilt on more than 170 years of industrial tradition

Our vision

is to be "The preferred partnerfor solutions in the oil and gas industry" through living ...

Our values

Customerdrive

HSE mindset

Peopleand teams

Open anddirect

dialogue

Hands-onmanage-

ment

Delivering results

Building customer

trust is key to our business

We take personalresponsibility forHSE because

we care

All our majorachievements

are team efforts

We encourageearly and honestcommunication

We know ourbusiness and get

things done

We deliverconsistently and

strive to beatour goals

In Brief

© 2011 Aker Solutions part of AkerIn Brief

Slide 9

Engineering solutions

Engineering provides full field development understanding, front-end design and conceptual engineering

Slide 9

Aker Solutions’ main offerings

Product solutions

Field-life solutions

Subsea production systems and lifecycle services, wellheads, controls, manifolds and tie-in systems

Drilling technologiesincl. full range of drilling equipment, drilling riser solutions and related products.

Process systemstechnologies within water injection, gas processing conventional and heavy oil treatment, produced water and sand handling and others.

Well intervention services incl. wireline, wireline tractor, logging, light well intervention etc.

Oilfield Services & Marine Assets offers deepwater well intervention services and subsea construction.

Maintenance, Modifications & Operations specialist who help oil companies reduce operating costs and extend life-of-field.

Umbilicals Static and dynamic umbilicals and subsea power cable systems for the oil and gas sector

Mooring and loading systems supply design, engineering and supply of innovative deck machinery.

© 2011 Aker Solutions part of Aker

Aker Solutions Asset Integrity Management (AIM)

Maintenance Planning

Execution

Inspection & Monitoring

Analysis & Improvement

MaintenancePhilosophy & Strategy

Maintenance programme &

budget

OPEX

CAPEXData base

I ICCPE

Design Integrity

Asset Integrity Management Services

Maintenance frame agreement contractor

...is differentiated by providing AIM services from well to shore throughout the entire life cycle

Maintenance & Inspection Engineering

Technical Integrity analysis & studies

Data Management, Systems & Tools

Advanced Inspection & Monitoring Technology

In-Service Inspection & Corrosion Management

Structural Integrity Management

Subsea Integrity Management

Fabrication & Weld Inspection (NDT)


Content



§ 45VedlikeholdDen ansvarlige skal sikre at innretninger eller deler av disse holdes ved like, slik at de er i stand til å utføre sine tiltenkte funksjoner i alle faser av levetiden.

§ 46KlassifiseringInnretningers systemer og utstyr skal klassifiseres med hensyn til konsekvensene for helse, miljø og sikkerhet av potensiellefunksjonsfeil.For funksjonsfeil som kan føre til alvorlige konsekvenser, skal den ansvarlige identifisere de ulike feilmodiene med tilhørende feilårsaker og feilmekanismer, og anslå feilsannsynlig-heten for den enkelte feilmodusen.Klassifiseringen skal legges til grunn ved valg av vedlikeholdsaktiviteter og vedlikeholds-frekvens, ved prioritering av ulike vedlikeholdsaktiviteter og ved vurdering av reservedelsbehov.

§ 47VedlikeholdsprogramFeilmodi som utgjør en helse-, miljø- eller sikkerhetsrisiko, jf. § 44, skal forebygges systematisk ved hjelp av et vedlikeholdsprogram.I programmet skal det inngå aktiviteter for overvåking av ytelse og teknisk tilstand, som sikrer at feilmodi som er under utvikling eller har inntrådt, blir identifisert og korrigert.Programmet skal også inneholde aktiviteter for overvåking og kontroll av feilmekanismer som kan føre til slike feilmodi.

§ 48Planlegging og prioriteringDet skal utarbeides en samlet plan for utføring av vedlikeholdsprogram og korriger-ende vedlikeholdsaktiviteter, jf. styringsforskriften § 12.Det skal foreligge kriterier for setting av prioritet med tilhørende tidsfrister for utføring av de enkelte vedlikeholdsaktivitetene. Kriteriene skal ta hensyn til klassifiseringen som nevnt i § 46.

Bakgrunn - Aktivitetsforskriften

http://www.ptil.no/aktivitetsforskriften/aktivitetsforskriften-n-article3849-379.html�

http://www.ptil.no/styringsforskriften/styringsforskriften-n-article3857-382.html�

http://www.ptil.no/aktivitetsforskriften/aktivitetsforskriften-n-article3849-379.html�


Bakgrunn – Vedlikeholdsstyringssløyfa,Ref. Basisstudien, OD1998


Risk Based InspectionStart

Scope Development

Team selection

RBI Screening workshop

Screening consequence

level

Documents & data for

RBI

Level 2 RBI assessment

Risk level / inspection plan

OK?


OK?

Detailed inspection planning

End

Significant

Yes

Yes

No

No

Insignificant

Screening probability

levelInsignificantSignificant

Documents and mechanical

data

Corrective maintenance

Planned Corrective

maintenance

Upload to CMMS &

CIMS

oo Integrity / inspection philosophyo risk matrix definitiono

Estimate PoF & CoF according to risk matrix definition

Review engineering of

item


levelSignificant Insignificant

Monitor for PoF drivers

PoF assessment

CoF assessment


Risk Based Inspection Framework:

• RBI in accordance with DNV RP-G101 and API580/581

• Secure optimum availability at acceptable risk

• Prioritize inspection efforts on the items driving the risk

• Document the evaluation leading to definition of inspection and condition monitoring programs

• Can be used to inform relevant stake holders, e.g. governments, owners, management, technicians

• An inspection framework based on RBI, and formalized through implementation of RBI and inspection management software, as well as computerized maintenance management system, gives a holistic view and is a powerful tool, for management and reporting of asset technical condition



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


RBI work process: Scope development, agreement of procedures and team definition

• Scope in detail: Items to be included, as well as detailed deliverables

• RBI Team to include correct competence and experience:

•Project management

•Risk Based Inspection

•Materials and corrosion

•Safety risk analysis

•Process and operation of the plant

•NDT and inspection planning

•Field inspection

•Maintenance

•CMMS and database management



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


RBI work process: Data collection -Documents and mechanical data:

• General data (e.g. system definitions, area definitions, material specifications, insulation specification, coating codes, risk matrix, company specific philosophies etc.)

• Equipment specific data (e.g. equipment design parameters for temperature and pressure, dimensions, materials, coatings, insulation, product codes, location etc.)



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


Example risk matrices:

Refer API 581:

Example - Fit to specific customer:PoF Catup to Cat A B C D E

1 5 M H H H H1,00E-01 4 M M H H H1,00E-02 3 L M M H H1,00E-03 2 L L M M H1,00E-04 1 L L L M M

CoF Category



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


RBI work process: RBI Screening:

• High level evaluation to identify hazards and assign each equipment tag to an integrity strategy

•Detailed RBI (sign. PoF and CoF)

•Condition monitoring (insign. PoF, but sign. CoF)

•Planned corrective maintenance(significant PoF, but insignificant CoF)

•Corrective maintenance (insign. PoF and CoF)

PoF – Probability of Failure

CoF – Consequence of Failure



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


RBI work process: Detailed RBI / “level 2”

• Semi-quantitative RBI analysis. Level of quantification to be agreed with customer

• Assessments performed on equipment / corrosion circuit using available information, e.g. actual process conditions, operational history, inspection history and findings



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


RBI work process: “Level 3 RBI assessment”

• Where the detailed RBI indicates unacceptably high risk or unacceptably frequent inspection, a detailed study of the risk drivers is carried out

• Recommendation of mitigating actions, e.g. equipment modifications, process changes, operational changes



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


RBI work process: Inspection planning and implementation in CMMS

• Detailed inspection planning providing details on inspection intervals and time for inspection, inspection method, areas for inspection (including inspection drawings), how it shall be reported etc.

• Inspection activities should be planned together with other maintenance activities where these have dependencies

• Required procedures and work task descriptions



Scope Development

Team selection



level


RBI



OK?


OK?


End

Significant

Yes

Yes

No

No

Insignificant




data


Planned Corrective

maintenance

Upload to CMMS &

CIMS




item




PoF assessment

CoF assessment


RBI work process: Condition monitoring program

• Establish integrity operating envelopes in order to verify validity of RBI analysis and check PoF drivers against pre-defined limits

• Define monitoring parameters on instrument tag level / test points etc.

• Monitoring to be focused on “significant influence factors”, e.g:

• Corrosion / erosion probes; e.g. erosion coupons, corrosion coupons, bacteria coupons

• Vibrations / stress monitoring

• Process parameters; e.g. pressure, temperature, velocity, pH, oxygen content, fluid conductivity, CO2, H2S etc.

• Performance parameters; e.g. heat transfer, pressure drop, chemical injection pump availability

© 2011 Aker Solutions part of AkerFebruary 2011 Slide 23Slide 23

Cost-benefits of process- and condition monitoring for static mechanical process equipment: a case study■ It is recognized that heat recovery units (HRSG) systems have

experienced significant problems due to leaks from water / steam piping and heat exchangers.

■ Main degradation mechanism have been stress corrosion cracking and corrosion fatigue in stainless steel pipes (SS316 / SS321) and flow assisted corrosion in carbon steel pipes.

Date Month 2011 Slide 23


Cost-benefits of process- and condition monitoring for static mechanical process equipment: a case study (cont)■ It has been recognized that monitoring of significant influence

factors (conductivity, pH, oxygen content, nitrite content) and acting on “out of spec” parameters could have prevented leaks

■ Leaks and shutdown of steam loops implicates that electricity has to be generated from gas driven generator

■ Calculations from one installation offshore Norway indicates an extra cost of $ 13-17 mill per year due to lost heat generation, as well as $ 35-50 mill in modification costs



Content



CMMS

Strategise

FMECASRCMRAMSLCCMTTFPFCRLSparesFailure Analysis

RBI RCM

AMST


CMMS

Monitor Static Equipment

Inspector

InspectionsUltrasonicsRadiographyStrainVisualVibration AcousticsCorrosionProcess


Exceptions

DesicionSupport

RBI RCM

AMSTInspector S-Pro

I.S. Data CollectorCMDM 5660

Infrared Camera

Ultrasonics


CMMS

Monitor Rotating

Analyst

VibrationLube OilPerformanceStrainElectricalBalanceAlignmentBearing Inspection


RBI RCM

AMST

Exceptions

DesicionSupport Protection

On-line

Off-line

Wireless


Reporting

Exceptions

DesicionSupport

Static Rotating

Results Reporter

Client Meeting RCARCFA

Exceptions

DesicionSupport

OPC OPC

CMMS

Planning Board

Planning


Integrasjon Router

Dashboard

OPC OPC

DCS(distributed controls system)

To @

Pi

SCADA (supervisory control and data acquisition)

To @

Smart Signal


Inspector S-ProI.S. Data Collector

CMDM 5660

Protection

On-line

Off-line

CMMSAnalystInspector

VibrationLube OilPerformanceStrainElectricalBalanceAlignmentBearing Inspection


Exceptions

DesicionSupport

Static Rotating

Results Reporter

RCFA RCAClient Meeting

Planning Board

RBI RCM

AMST

Integration Router

Exceptions

DesicionSupport

Dashboard

OPC OPC

Wireless

SCADA (supervisory control and data acquisition)

Smart Signal

DCS(distributed controls system)

Pi

Infrared

Ultrasonics

Eddy Current Inspectionof tube stack

InspectionsUltrasonicsRadiographyStrainVisualVibration AcousticsCorrosionProcessThermography


Content



Non-Intrusive inspection (NII)■ Where the RBI identifies internal degradation mechanisms which can be

followed up through periodic inspection, it should be evaluated whether inspection can be performed non-intrusively

■ Non-Intrusive Inspection means inspection from outside, without breaking the integrity. Performed during production (or during shut down)

■ Assessment can be performed in accordance with DNV RP-G103, Non-Intrusive Inspection

■ AkerSolutions have developed a NII screening methodology considering ● Technical issues (design / construction data, inspection history etc)● HSE issues● Business issues (cost – benefit evaluations)

■ Why NII?● Reduce need for entering of confined space (safety of personnel)● Increase production availability● More flexibility in planning of shut down work

■ NII assessment capabilities will be implemented in AkerSolutions RBI and inspection management software


Cost-benefits of Non-Intrusive Inspection: a case study


::.

Item Electrostatic coalescer, tag No. XXXX-VJ20001A

Presumptions and experience

■ Entering tank for IVI will be done outside revision stop, while producing through parallel coalescer

■ In order to secure acceptable water in oil content, the production is reduced by 3-5000 barrels per day for about 20 days

Evaluation ■ IVI implicates an accumulated deferred production of $ 5-10 mill while NII does not affect the production

■ The inspection cost for IVI and NII is about the same ($ 0.22 vs. 0.18 mill)

■ Manpower required for IVI and NII is about the same (4 vs. 5 persons, about 20 days)

■ The risk related to entering the tank is significant wrt. personnel, and redundancy is lost while performing IVI. Risk related to NII is low

Conclusion There is a potential for significant savings, both in terms of risk and production, by implementing NII


Risk Based InspectionDynamic optimisation of inspection plans

■ Extend service life and verify safe operation of an asset by a combination of analysis, monitoring and inspection

■ A systematic use of available process- and condition monitoring data, available technology and Non-Intrusive Inspection in order to give better production availability while securing acceptable risk

■ Use integrated planning as a tool to dynamically optimisemaintenance- and inspection plans


CopyrightCopyright of all published material including photographs, drawings and images in this document remains vested in Aker Solutions and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.

DisclaimerThis Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions of the regions and industries that are major markets for Aker Solutions ASA and Aker Solutions ASA’s (including subsidiaries and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements containing words such as “expects”, “believes”, “estimates” or similar expressions. Important factors that could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that are or will be major markets for Aker Solutions’ businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Aker Solutions ASA believes that its expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation. Aker Solutions ASA is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation, and neither Aker Solutions ASA nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use.Aker Solutions consists of many legally independent entities, constituting their own separate identities. Aker Solutions is used as the common brand or trade mark for most of these entities. In this presentation we may sometimes use “Aker Solutions”, “we” or “us” when we refer to Aker Solutions companies in general or where no useful purpose is served by identifying any particular Aker Solutions company.

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