VAIL-Plant Software Description
Transcript of VAIL-Plant Software Description
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Short Description
Of
VAIL Plant Software(RBI plus Inspection Data Management System)
Velosi Certi fication Services LLC
25 AUGUST,2010
Velosi Asset Integrity Management Services
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TABLE OF CONTENTS
1. INTRODUCTION (VAIL-PLANT)....................................................................................... 4
2. PRESSURIZED EQUIPMENT MANAGEMENT SYSTEM (PEMS) ................................ 6
3. PRESSURE SAFETY VALVES INTEGRITY MANAGEMET SYSTEM (PSVMS) ........ 7
4. LIFTING EQUIPMETN MANAGEMENT SYSTEM (LEMS)........................................... 7
5. CIVIL INSPECTION MANAGEMENT SYSTEM (CIMS) ................................................ 8
6. FACILITY STATUS INTEGRITY REPORT (FSIR) .......................................................... 8
7. ELECTRICAL, INSTRUMENTAL AND ROTARY MANAGEMENT SYSTEM (EIRMS)
8
8. STRUCTURE INTEGRITY MANAGEMENT SYSTEM (SIMS) ...................................... 9
9. PIPELINE INTEGRITY MANAGEMENT SYSTEM (PIMS) ............................................ 9
6.1 WHYPIPELINEINTEGRITYMANAGEMENT?............................................ 10
6.2 VELOSIS PIPELINE INTEGRITY MANAGEMENT SYSTEM..................................... 10
6.3 BENEFITSANDFEATURES ....................................................................... 10
6.4 KEYFEATURES .......................................................................................... 10
6.5 DATAMANAGEMENT ................................................................................. 11
6.6 RISKASSESSMENTS.................................................................................. 11
6.7 LONGTERMINSPECTIONPLANNINGANDMANAGEMENT ................... 116.8 SURVEYSRECORDINGCATEGORIES...................................................... 11
6.9 EXTERNALCORROSIONDIRECTASSESSMENT(ECDA) ....................... 12
6.10 INTERNALCORROSIONDIRECTASSESSMENT(ICDA)....................... 12
6.11 STRESSCORROSIONCRACKING(SCC) ............................................... 13
10. HULL INTEGRITY MANAGEMENT SYSTEM .............................................................. 13
11. WELL HEAD INTEGRITY MANAGEMENT SYSTEM ................................................. 14
12. CATHODIC PROTECTION & MONITORING SYSTEM .............................................. 16
13. KPI (KEY PERFORMANCE INDICATORS) SYSTEM .................................................. 16
14. ROOT CAUSE ANALYSIS (RCA) SYSTEM .................................................................... 17
15. ESTIMATED CORROSION RATE ANALYSIS ............................................................... 17
16. INSPECTION MANAGEMENT ( PIR MODULE) ........................................................... 17
17. SYTEM INTEGRATION/INTERFAC ING ....................................................................... 18
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12.1 SAP INTEGRATION AND INTERFACES ................................................................. 18
12.2 API RISK BASED INSPECTION SOFTWARE.......................................................... 18
12.3 DATA LOGGER ........................................................................................................... 18
18. INSPECTION SCHEDULER .............................................................................................. 18
19. MAINTENANCE PACKAGE ............................................................................................. 18
20. STANDARD REPORTS ...................................................................................................... 19
21. AD-HOC REPORTS (USER DEFINED REPORTS) ......................................................... 19
22. REFERENCE LIBRARIES ................................................................................................. 19
23. NORSOK M-506 CO2 CORROSION MODEL ................................................................. 19
24. INTEGRITY PARAMETERS TRENDS REPORTING .................................................... 19
25. SYSTEM USERS & USER GROUPS ................................................................................. 20
26. DATA RECORDING BUSINESS LOGIC.......................................................................... 20
27. SOFTWARE REQUIREMENTS ........................................................................................ 20
28. HARDWARE REQUIREMENTS ....................................................................................... 21
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1. INTRODUCTION (VAIL-PLANT)
Oil & Gas Industries need to manage a complex portfolio of risks. These range from minor events to major
incidents that may involve serious personnel injuries, significant environmental damage or substantial financial
impact. Globally, the Oil & Gas Industry has been relatively successful in managing major incident risk.
Nevertheless, the challenge remains to reduce the likelihood of such events.
This program is mainly developed for Oil & Gas Industry to maintain the records and reduce the risk (injuries,
environmental damage etc.) of all the equipments in the plant. Plant contains Pressurized equipments, Pressure
safety valves and Pressure relief valves, Tank, Vessels, Heat Exchangers, Heaters, Columns, Pipes, Reactors,
Fin Fan Coolers, Drums, Structures, Boilers, Chimney, Flares, and Cranes etc. These equipments contains
engineering data, operating data, analysis data, history data (Inspection, Failures and Replacements data) ,
inspection results and maintenance routine data.
Risk Based Inspection is a method for using risk as a basis to prioritize and manage the efforts of an inspection
program. An effective risk based program results in a reduced level of risk for a given level of inspectionactivity. In any operating plant, a relatively large percentage of the risk is usually associated with a small
percentage of equipment. A Risk Based Inspection methodology permits the shift of inspection and maintenance
resources to provide a higher level of coverage on the high risk items and an appropriate effort on lower risk
equipment.
Being risk-based, the method requires consideration of both the probability of failure as well as the
consequences associated with failure. The methodology can be applied to process equipment, structures and
pipelines. The main deliverable of an RBI study is an Inspection Program, describing:
Prioritization of equipment items to inspect.
When to inspect these items (inspection interval).
Which method to use for the inspection.
The VAIL-Plant Software is developed as part of the Velosi Risk Based Inspection Services and intended to be
used for:
Risk ranking and risk matrix.
Risk driving degradation methods.
Probability of failure and consequences for each individual equipment item.
Calculates consequence to personnel, environment, production loss and material damage for ignited
and unignited leaks.
Evaluation of the impact of changes in process conditions and materials on installation risk and
inspection programme.
Effect of inspection effectiveness and the number of inspections on the individual equipment itemrisk for a given period of time.
Inspection guidelines and detailed equipment inspection plans can be derived.
Inspection Plans generation based on engineering measures.
Inspection History Management.
Man hour resource planning of on stream & off stream Inspection.
Inspection results analysis based on Reliability Data.
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The development idea behind the VAIL-Plant is, How to manage all types of equipments of Oil & gas industries
in effective software. It covers all the equipments in each separate modules based on their functional &
operational features. There are following modules in VAIL-Plant:
Pressurized Equipment Management System (PEMS)
It covers Pipes, Column, Tank, Fin-fan cooler, Heat exchanger, Heater, Reactor, Vessel, Flares,
chimney etc.
Structure Integrity Management System (SIMS)
It covers all type of Structures.
Pressure Safety Valve & relief Valve Management System (PSVMS)
It covers Pressure Safety Valves (PSV) and Pressure Relief Valves (PRV).
Lifting Equipment Management System (LEMS)
Civil Inspection Management System (CIMS)
Facility Status Integrity Report (FSIR)
Electrical, Instrumental and Rotary Management System (EIRMS)
Miscellaneous Equipment Management System (MEMS)
It covers POs /FOs, NRVs and other equipments based on the functions of plant.
Pipeline Integrity Management System (PIMS)
Hull Integrity Management System
Wellhead Integrity Management System
It covers all types of Pipelines and their components, crossings, joints & attached equipments.
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2. PRESSURIZED EQUIPMENT MANAGEMENT SYSTEM (PEMS)
The purpose of this document is to provide the PTT team with an overview of the Pressurized
Equipment Management System Module scope of work, and the software solution capability. This
includes the description of business processes and how a Velosis PEMS solution will enable these
processes.
Pressurized Equipment Management System includes the features:
Engineering data capturing along with hierarchy management of the facility
Risk assessment and inspection planning of static equipments as per API RBI
Semi quantitative RBI methodology for risk evaluation and inspection planning against
identified damage mechanisms compliance with API St. 580
Inspection history recording with respect to multiple positions and TMLs as well
Failure and replacement history recording
CP monitoring data recoding and evaluation.
KPIs identifications and calculation/evaluations
Short term/long term corrosion rate calculations
Remnant life calculations based on minimum measured thickness
Asset Integrity /RBI related documents management and capturing of drawings, isometrics,
PFDs and P&IDs
Reference documents attachment.
Trends and console reporting
Plant Inspection Requirements (PIRs) generation
Root Cause Analysis (RCA) against failures
Time, Cost & Resources (CTR) Management
Data importing from excel workspace templates
Risk Based Inspection (RBI) is a systematic approach to create an accurate, well targeted inspectionstrategy based on risk. The inspection plans developed are to mitigate the specific failure mechanisms
identified. It is applicable to offshore & onshore installations such as fixed or mobile units as well as
FPSOs and pipelines.
The oil & gas, process industry handles a wide range of flammable and toxic materials which are
potentially hazardous. To reduce the hazards to an acceptable level, the authorities through
legislation, have imposed requirements on the management of plants and facilities, requiring it to
demonstrate that it has identified the existing hazards and undertaken mandatory inspection and
mitigation measures to prevent accidents.
In the cyclic nature of the business, operators constantly find themselves having had to balance
between meeting the regulatory requirements to shutdown and avoiding business interruption. Those
plants that succeed in operating more efficiently and reliably will be better positioned to ensure longterm survival and success. Increasingly, innovative asset integrity strategies such as RBI are being
implemented to meet these goals.
VELOSIs Asset Operations Process is based on a risk-based strategy for maintenance and inspection
planning (i.e. time-based, condition-based, operational or corrective maintenance). These strategies
are associated with company and plant objectives towards plant availability and safety. Risk-based
methods like Reliability, Availability and Maintainability (RAM), Reliability Centred Maintenance
(RCM) and Risk Based Inspection (RBI) can be used to rank systems and equipment and develop
strategies for maintenance and inspection.
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The outcomes from RBI and Inspection Management System;
Risk ranking, risk matrix & pareto curves.
Risk driving degradation methods.
Probability of failure and consequences for each individual equipment item. Calculates consequence to personnel, environment, production loss and material damage for
ignited and unignited leaks.
Evaluation of the impact of changes in process conditions and materials on installation risk
and inspection program.
Effect of inspection effectiveness and the number of inspections on the individual equipment
item risk for a given period of time.
Inspection guidelines and detailed equipment inspection plans can be derived
The benefits of RBI and Inspection Management System;
Establish risk ranking among individual equipment items in order to optimise inspection efforts
and reduce costs
o All pressure equipment contains flaws
o Most flaws are innocuous; just a few may cause critical failures
o Those critical flaws must be found cost effectively
Extend inspection intervals beyond statutory requirements
Potential for reduction of production loss during turnaround inspection
Increase confidence in equipment integrity
Established path to regulatory approval
3. PRESSURE SAFETY VALVES INTEGRITY MANAGEMET SYSTEM (PSVMS)
VAIL-Plant has a module for pressure safety valves integrity management. It maintains;
Hierarchy of the valve(PSV/ PRV)
Design/engineering data
Inspection history recording
Risk evaluation
Inspection planning
Cost, time & Resource management
4. LIFTING EQUIPMETN MANAGEMENT SYSTEM (LEMS)
VAIL-Plant has the module for Risk Based Inspection of lifting equipments like cranes, etc. It
includes,
Hierarchy recording and management
Design / Engineering data capturing Operational data recording
Risk evaluation against identified damage mechanisms
Inspection planning
Reporting feature
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5. CIVIL INSPECTION MANAGEMENT SYSTEM (CIMS)
VAIL-Plant has a module for Management of Civil assets like Concrete Structures, Pipe Sleeper,
Buildings, Fencing, Roads & Paving, Equipment Foundation, Pipe Track Foundation etc. It includes,
Hierarchy recording and management Design / Engineering data capturing
Defects Recording
Risk evaluation against identified Defects
Defect Assessment and Repair plan
Cost estimation against Defected area
Reporting feature
6. FACILITY STATUS INTEGRITY REPORT (FSIR)
VAIL-Plant has a module to see the overall facility status report against trips/failures, Anomalies,
Backlogs etc. It includes,
Hierarchy recording and management
Each hierarchy level have divided into three groups (HSECS, HCS, Non HCS)
Number of leaks for last 30 days and to date against hierarchy each level
Number of trips/failures for last 30 days and to date against hierarchy each level
Number of Anomalies for last 30 days and to date against hierarchy each level
Number of equipments (Remnant life =2 & 7 years) for last 30 days and to date against hierarchy
each level
Number of equipments (MTBF 7 years) for last 30 days and to date against hierarchy each
level
Backlogs Inspection activities for last 30 days and to date against hierarchy each level
Backlogs PM activities for last 30 days and to date against hierarchy each level
7. ELECTRICAL, INSTRUMENTAL AND ROTARY MANAGEMENT SYSTEM (EIRMS)
VAIL-Plant has a module of Reliability Centered Maintenance (RCM) for Electrical, Instrumental andRotary equipments like Generator, Pressure gauge and turbine etc. It includes,
Hierarchy recording and management
Design / Operational data capturing
Functional data recording
Reliability operator and reliability generic data recording
Failure mode and effect analysis based on equipment type
Failure mode, effect and criticality analysis and their criticality matrix
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Plant Maintenance Routines (PIR) generation
Work order and work packs generation
Inspection history recording
Maintenance history recording
Failures and Replacements recording Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR) calculation
Effective Reporting
8. STRUCTURE INTEGRITY MANAGEMENT SYSTEM (SIMS)
VAIL-Plant has the module for Risk Based Inspection of lifting equipments like cranes, etc. It include,
Hierarchy recording and management
Design / Engineering data capturing
Operational data recording
Risk evaluation against identified damage mechanisms
Inspection planning
Reporting feature
9. PIPELINE INTEGRITY MANAGEMENT SYSTEM (PIMS)
The purpose of this document is to provide the company team with an overview of the Pipeline
Integrity Management Module scope of work, and the software solution capability. This includes the
description of business processes and how a Velosis PIMS solution will enable these processes.
Whenever the term Oil & Gas appears, it shall be interpreted to fulfill requirements of Oil & Gas
Industry.
The primary modules enabled by Velosis PIMS are:
Pipeline profile recording and plotting Probability of Failure (POF) calculation and plotting along the pipeline (POF Vs TIME)
against applicable damage mechanism
Consequence of Failure (COF) calculation against applicable damage mechanism
External Corrosion Direct Assessment (ECDA)
Internal Corrosion Direct Assessment (ICDA)
Risk assessment against third party damages
Risk assessment against Stress Corrosion Cracking (SCC)
Corrosion calculation (NORSOK M-506)
Inline inspection analysis
Asset management
Scheduling of integrity management and inspection Cost, Time and Resources (CTR) management
Standardized reporting features
VAIL-Pipeline is a composite application designed for pipelines integrity management. VAIL-Pipeline
provides a structured work process which allows the organization to define inspection strategies
based upon Risk Based Inspection (RBI) principles. In addition, VAIL-Pipeline provides specific
capabilities to evaluate and measure the effectiveness of inspection strategies using analytics which
provides a closed loop, continuous improvement process.
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VAIL-Pipeline provides a framework that allows conducting pipeline risk based analysis for
components, sections and whole line as well. In addition the system is flexible, allowing clients the
flexibility to configure a specific criticality matrix to suite their specific business process needs.
VAIL-Pipeline will support the analysis and creation of inspection strategies that are to be
implemented. The application will permit the reviewing and adjustment of strategies to meetadditional or new requirements from the RBI analysis system.
Contents of this document are confidential and proprietary.
6.1 WHYPIPELINEINTEGRITYMANAGEMENT?
Pipelines are subject to regular statutory inspections, verifications and re-certifications just as often as
facilities containing and transporting hazardous products as well as pressure equipment. Until
recently, such requirements have been enforced and have imposed pressure testing of oil pipelines to
occur every ten years. Operators are now asked to have in place a comprehensive integrated Pipeline
Integrity Management (PIM), which is more in depth than an inspection and maintenance program,
but a management system encompassing engineering, operation, inspection, maintenance, HSE and
Corporate communications.
6.2 VELOSIS PIPELINE INTEGRITY MANAGEMENT SYSTEM
VELOSI brings a wealth of experience in many integrity management related fields such asHSE, system certification, risk assessment, fitness for services evaluation, risk based
inspection and maintenance.
VELOSI brings together all the skills. Expertise, operation support and local presence to ourclients the best PIMS available on the market.
Its a best available solution for Pipeline Integrity Management that facilitates for both onshoreand offshore pipelines.
User friendly inspection management tool.
Optimum inspection periods are formally obtained based on an implicit time dimension of risk.
6.3 BENEFITSANDFEATURES
Meeting customer needs is Velosis ultimate business objective. Main benefits and features of VAIL-
Pipeline can be summarized are as follow:
Implements company specific inspection strategies and best practices
Reduces risk for non-planned shut downs
Increases reliability and availability
Provides the management with an aggregated overview of asset integrity
Scalable to meet company specific work processes and asset portfolio
Common storage for all life cycle data
Benchmarking internally or against external best practice
6.4 KEYFEATURES
The major functional modules of VAIL-Plants PIMS include:
Data management
Analysis tools and code checks
Risk assessments
Planning and inspection management
Built-in library of form such as corrosion mapping, SSC
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Dialogs based input forms, DCVG & CIP information recording, SSC & MIC information
recording,
Coating fault information
Metal loss assessment
Soil receptivity & pH values Event log
Surveys & inspection results,
Defect assessment & condition assessment
Short term and long term inspection planning
Dynamic reporting features.
Key support functions include document management, integration interfaces and a project
execution environment
6.5 DATAMANAGEMENT
Velosis PIMS is based on the PODS data model with an offshore/onshore extension to cater for
offshore/onshore objects like e.g. risers and subsea templates. The database is enveloped by a securitysystem and role-based access restrictions on pipelines and groups of pipelines ensuring integrity of
information. A specifically powerful capability in Velosis PIMS is the dynamic segmentation of
pipelines associated with varying profiles such as location classes, pipeline sections and other specific
user definition. The dynamic segmentation function is essential to the effectiveness and flexibility of
the system.
6.6 RISKASSESSMENTS
PIMS module supports the semi-qualitative risk assessment methodology and provides selected
quantitative risk assessment functions to qualify and document interpretations on the PoF scoring and
resulting risk levels. Threats, CoF and PoF can be based on various segmentation principles, such as
pipeline sections, location and safety class, entire pipeline and also refined, adjusted by the pipelineengineer. The resulting risk will be displayed along the pipeline for each projected year. The risk
assessment for components and critical areas (hotspots) can be performed in both overview and
detailed mode.
6.7 LONGTERMINSPECTIONPLANNINGANDMANAGEMENT
The inspection planning module provides the engineer with functions to define inspections targeted
for the entire pipeline or some selected sections. The long-term inspection plan is calculated from a
combination of the risk assessment results and the prescribed inspection intervals.
6.8 SURVEYSRECORDINGCATEGORIES
Using the Velosis Pipeline Integrity Management Software, surveys can be recorded by segregatingon the basis of desired outcome. The surveys monitoring parameters classification supported by
VAIL-Plants PIMS module are:
Metal loss single
Anode depletion
CP readings
Vertical configurations
Vertical out-of-straightness
Feature findings
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Component Observation
Exposure
Others
6.9 EXTERNALCORROSIONDIRECTASSESSMENT(ECDA)VAIL-Plants PIMS module covers the following ECDA surveys regarding inspection management &
to analyze the likelihood and impact of pipeline failures caused by external corrosion.
Soil Resistivity Analysis
Structure to soil Analysis
DCVG Survey
ACVG Survey
Pearson coating survey
CIP (Close Interval Potential) survey
Pipe to soil potential survey
C Scan current attenuation Pipeline current mapper
6.10 INTERNALCORROSIONDIRECTASSESSMENT(ICDA)VAIL-Pants PIMS module covers the Internal Corrosion Direct Assessment regarding inspection
management & to analyze the likelihood and impact of pipeline failures caused by internal corrosion.
For ICDA the PIMS module has the capability be recorded the following necessary data for the
pipeline:
Construction Related Data
o Removed taps
o Locations of inputs and outputs to the pipeline
oYear of construction
o Locations of drips
o Existence of flow coatings
o Diameter and wall thickness
o Length/Map
o Location of compressors
Elevation Profile (Topography)
o Depth of cover preferred
o Elevation changes from roads, rivers, drains, valves, drips
Process Information
o Change in gas flow direction Minimum and maximum Operating pressures
o Gas flow rates - maximum flow rates at minimum and Maximum operating pressures
o Liquid water flow rateo Liquid hydrocarbon flow rate
o Temperature
Maintenance Data
o Pigging type and frequency
o Presence of solids
o Presence of glycol
Inspection and Repair Data
o Leaks
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o Hydro test and ILI data if available
o Replacement or sleeve repair
o Dig site inspections
Chemical Treatment
oYears of treatment
o Type of chemical (biocide, inhibitor) and properties (e.g., oil soluble)
o Continuous or Batch (dosage and frequency)
Sampling Data
o Gas analyses
o Solids
o Liquids
o Solids
o Bacteria testing results
Corrosion monitoring data
o Coupons
o Probes
6.11 STRESSCORROSIONCRACKING(SCC)VAIL-Plant has the module for POF, COF and risk assessment for stress corrosion cracking based on
coating type, age and specified yield strength factor.
10. HULL INTEGRITY MANAGEMENT SYSTEM
Ship owners and managers strive to maintain a high level of structural integrity. The ship crews and
shore staff perform inspections of hull structure on a regular basis to assess the hull condition. The
inspection regimes require easy identification of problems. Besides owners, inspections and surveys
are carried out by many agencies such as classification societies, insurers, vetting agencies, cargo
surveyors, port state, coastal state and flag state authorities.
All have an interest in the safe operation of the ship and ensuring that it is properly maintained. The
effectiveness of these inspections is being continually challenged by the ever decreasing time that these
vessels remain in port. In this paper a holistic, simple and quantifiable approach is proposed. This
methodology employs the application of risk-based decision-making techniques. Risk-based
techniques have demonstrated great potential in identifying key structural elements and focusing
resources for maintenance and inspection. The proposed methodology for rationalizing the hull
inspection program is via the development of a vessel-specific inspection program which includes a
scoring system for identified inspection criteria and a list of target inspection areas (critical structural
areas) for each compartment. The condition for each inspection criteria, depending upon the score, is
displayed within the context of a simple traffic light system. This methodology can be applied by a
trained and qualified owners representative. The scoring system can be utilized and analyzed to viewthe condition status of compartments, vessels, and a fleet. The scoring system also utilizes a system to
trigger anomaly list generation, which can be used to manage the damages and repairs as well as
create a repair list for future repair / drydock events.
The shipping industry needs a rationalized approach to perform inspections of hull structure and a
methodology on what to inspect, when to inspect, where to inspect and how much to inspect. The
benefits of hull inspection are usually well answered and known to all the inspection agencies.
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Traditionally ship owners and vessel managers have their in-house hull inspection schemes and
programs to track, assess and maintain the hull structure. Inspections to assess hull condition are also
performed by many agencies such as classification societies, insurers, vetting agencies, cargo
surveyors, port state, coastal state and flag state authorities.
The inspection module for Hull within VAIL-Plant has the following features/capabilities;
A compartment is divided into zones similar to the area of consideration
All compartments are divided into zones those can be inspected and graded for the inspection
criteria
Six inspection criteria have been identified for each compartment & these are inspected for
each zone.
Critical structural areas (if any) are identified for a compartment/zone based on engineering
analysis and in-service experience.
The inspection criteria are graded with a score (rating) from 0 to 6. A traffic light status (red
5 to 6, yellow 3 to 4, green 0 to 2) is assigned to each zone for each criterion.
These scores are added for each zone and rolled up to get a normalized score for the
compartment. A red signifies the presence of an anomaly which needs to be documented for
resolution/rectification.
Six inspection criteria for the Hull structure;
o Coating Condition
o General Condition
o Pitting/Grooving
o Deformation
o Fractures
o Cleanliness (House Keeping)
System has the capability to identify the general inspection activities and inspection activities
for critical area as well.
Damage mechanisms identification for each zone & risk evaluation Inspection history recording
Maintenance history recording
Replacements history recording
Failure history recording
Hull Inspection Routines (Inspection Packs) definition and execution
Reporting feature
11. WELL HEAD INTEGRITY MANAGEMENT SYSTEM
The objective of developing Well Integrity Management System (WIMS) is to provide standard
guidelines to ensure that technical integrity of all the wells is maintained throughout their life cycle,
they operate under safe condition and are capable to function continuously to achieve the targeted
production/injection requirements. Well integrity is based on the establishment and maintenance of
confinement barriers in the particular well. As per WIMS standards, a well is considered integral if at
least two separate and sound confinement barriers across each flow path between the potential
reservoir and surface are available all the time.
WIMS very much emphasis on the problem prevention based approach (endeavour to predict & solve
the problem before it happens) that can accommodate several direct advantages and benefits like
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reduction in operating down time, enhancement in well control and safety aspects, minimized
unplanned repair intervention & cost impact etc.
Major well issues that impact on the technical integrity and operability of a well viz; Surface
Completion Components (Wellhead & X-mass tree), Sub-surface Completion Components (downholesafety valve (DHSV), Gas lift valves, electric submersible pump (ESP), Well Construction (Casing &
Annulus), Communication Problems, Corrosion, Scaling, Non-hydrocarbon Effluents / Products, Well
Operation Suspension, Well Intervention Services (Electric/Slick Line, Stimulation, coiled tubing unit
(CTU), Risk Management Process & Auditing System.
Many of the mature oil and gas production areas in the world are characterized by an aging well
stock. Poorly maintained wells can be a potential threat to people and the environment and can result
in economic loss through production deferment. At a time when high oil prices mean any downtime is
bad news, has WI ever been more important?
The inspection module for WIMS within VAIL-Plant has the following features/capabilities; Providing up-to-date information on the current well integrity status,
Looking closer at the functionality, the information available for an individual well is divided
into five main categories; Status assessments, operational history, well details, well monitoring
and non-conformance logs.
Each of these categories consists of a set of sub-categories, logically broken down into
manageable chunks of information.
The predefined key indicators are split into several status codes and give the user the means to
properly describe the well situation. The predefined codes are:
o Integrity Status
The well risk status indicates the level of risk the well has been assessed to have. The
integrity status is derived from risk assessment of the wells condition.o Well barrier status
This principle implies that at least two independent and testable well barrier envelopes shall
exist in a well.
o Annuli status
When an abnormal pressure behavior is detected and identified as a leak to an annulus, the
annuli status should be assessed and the status changed. Pressure build up may be caused
by e.g. a casing leak or micro annuli.
o Valve status
The valve status indicates the status of the safety valves in a well. These barrier elements
are periodically tested and will constitute a major part of the well barrier. Customized
reports on test information and test performance indicators are available as an add-on
module.
o Life cycle status
The lifecycle status states the operational phase of the well, i.e. if the well is operating or
handed over for workover / intervention or P&A. This documents the responsible
department for the well integrity throughout the wells lifetime.
VAIL-Plant (WIMS) offers the possibility to retrieve and present data from automatic and
manual sensor readings available for the well, e.g. automatic A- and B-annulus pressure
readings and manual C-annulus pressure readings. In addition to pressure, temperature, choke
position, wing valve position may be retrieved.
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For all available sensor readings, manual or automatic, the last read values are presented
graphically in a gauge together with the defined alarm limits.
VAIL-Plant (WIMS) enables the user to see trends in graphs, e.g. annuli and tubing pressures
and temperatures. In this way, VAIL-Plant (WIMS) simplifies the process of establishing trend
data for evaluation purposes. The graphs can also indicate other types of information such as the start-up of test activities or
build in logic to determine if the well is shut-in or flowing.
An important feature of VAIL-Plant (WIMS) is the possibility to store and present bleed-off
and top-up pressure data for annuli.
VAIL-Plant (WIMS) can in many ways be described as a portal to information relevant to well
integrity management. As part of this, VAIL-Plant (WIMS) has included a category with
typical background information to be used as input in well integrity assessments, e.g.
completion data, handover documentation, completion schematics etc. In addition, the well
details category is used to define the alarm limits in the well. These can either be connected
automatically from existing systems or entered manually.
An important part of VAIL-Plant (WIMS) is the ability to generate reports. In order to
accommodate the different requirements, VAIL-Plant (WIMS) can easily be configured to
generate customized reports. This combined with the ability to connect to and extract
information in various company databases makes VAIL-Plant (WIMS) a very flexible
reporting tool.
Several add-on modules are available, e.g. Scale management and Tubing deformation. These
modules will be customized to requirements.
12. CATHODIC PROTECTION & MONITORING SYSTEM
Velosi methodology for CP System is classified into two parts:
Data review & engineering works
Field works- surveys, inspections and investigations
Velosi has identified seven key steps to carry out evaluation & condition monitoring of CP
system:
Pre-Assessment study
Preparation of methodology and procedures
Technical audit of existing CP system installation of main pipelines & performance
assessment of Tank Form area, Pump stations facilities and associated piping network
On/Off potential survey, CIP survey and line current survey
Visual Inspection of Heat Shrinkable Sleeves.
13. KPI (KEY PERFORMANCE INDICATORS) SYSTEM
The following features of VAIL-Plants KPI module are described given below:
The system has capable to incorporate standard industry metrics such as Mean Time
Between Failure (MTBF), Mean Time Between Event, Equipment Reliability, Equipment
Availability as well as is flexible to allow user defined metrics based on the systems data
and other external data sources.
Supports metrics involving incidents and lost production.
Enterprise-wide metrics for maintenance, reliability, safety, environmental, health, asset
and financial problems
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Support and display a multilevel performance scoreboard
Support the building of Key Performance Indicators (KPI) and their display
Support the graphical display of all metrics
Alert company personnel when KPIs fall outside of established limits
Provide configured KPIs for the companyProvide automatic electronic interface to company production monitoring system to create production
KPIs14. ROOT CAUSE ANALYSIS (RCA) SYSTEM
The following features of VAIL-Plants RCA module are described given below:
Analysis the different types of failures events such as environmental, health, safety or
recurring equipment failures
Support multiple fault tree development and display methodologies as configured content
within the system
Maintaining the database of Team members, team goals and critical success factors for
the analysis
Ability to define standard templates to help facilitate the analysis of typical or previouslyexperienced failure events
Ability to collect, store, analyze, print and report failure data for an analysis
Ability to assign the task of collecting failure data to a team member and track any
outstanding task by team member, group,, area or analysis
Ability to visually analyze events by organizing failure modes, hypotheses and causes of
an event through the use of a logic tree
Charting tool to track the effectiveness of implemented recommendations
Closed loop tracking recommendation tracking from within the RCA solution
Ability to verify and communicate hypothesis to users.
15. ESTIMATED CORROSION RATE ANALYSISThe following features of VAIL-Plants ECR module are described given below:
Capable of calculating estimated corrosion rate according to applicable damage
mechanisms of a equipment based on services.
Capable of calculating susceptibility according to applicable damage mechanism.
16. INSPECTION MANAGEMENT ( PIR MODULE)
The following features of VAIL-Plants Plant Inspection requirements (PIR) module are described
given below:
Capable to manage inspection activities for all types of assets/ equipment (tags). The
system shall allow performing inspections on groups of tags, platforms and corrosion
loops. Allow users to plan, schedule and execute the PIRs. It automatically extracts inspection
plans from SAP.
Allow the users to create work scopes, work packages for execution of PIR on a tag or a
set of tags (package like boliers, pipe). Drawings, documents, specifications, previous
history schedule date, previous readings, previous anomalies etc.
Allow monitoring process of the PIR Plan.
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17. SYTEM INTEGRATION/INTERFAC ING
12.1 SAP INTEGRATION AND INTERFACES
The following features of VAIL-Plants SAP Integration module are described given below:
The VAIL-Plant have certified interface to SAP
Support an interface with SAP Plant Maintenance and Financial Software System
Capability to be configured for alerting based on preset criteria
Support to interface bi-directional of notification/ work order data from SAP into the
system
bi-directional synchronization of financial data into system
bi-directional synchronization of Location/ Equipment records from SAP to the system
Notification/ work request creation based on the systems criteria and/ or user interaction
Update to the systems location/ equipment source tables based on changes to SAP master
data records, including movement of equipment from one location to another
Automatically synchronize with SAP tag/equipment master data
Capable to link to SAP work notifications and allow automatic creation of notifications
Link from SAP work order completions and provide inspection costs
Automatically interface to SAP preventive maintenance plans
12.2 API RISK BASED INSPECTION SOFTWARE
System has the capability to be integrated with API RBI V8.02/8.03
VAIL-Plant can fetches the RBI results data in batch from API RBI Database
Pre-Requisites:
Equipment Tag for which RBI results have to be fetched must exist in VAIL-Plant
API RBI Database should be in SQL Server12.3 DATA LOGGER
System has the capability to be integrated with Inspection Data logger. ULTRASONIC
THICKNESS GAGE (38DL PLUS )
Spec.
Dual and Single Element ransducers
Rugged, designed for IP67
Thickness range from 0.08 mm (0.003 in.) to 635 mm (25 in.)
Color Transflective VGA Display
18. INSPECTION SCHEDULER
An Inspection order goes through the following process to be executed;
Planned against a RANGE of Dates
Approved for Inspection Scheduled Pending (Before exc. Date)
Scheduled-In progress (In 30 Days of Execution)
Completed (On Work order Closing)
Backlog (Passed 30 Days of Inspection Date)
Cancelled (Cancelled)
19. MAINTENANCE PACKAGE
A maintenance order goes through the following process to be executed;
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Filtering out the Tags for Maintenance Planning
Dispatch for Maintenance Work Order notification
Filtering would work based on remnant life
20. STANDARD REPORTSVAIL-Plant has the feature of built in standard reports those includes;
Piping - Equipment Summery Sheet
Vessel Equipment Summery Sheet
Column Equipment Summery Sheet
Heat Exchangers Equipment Summery Sheet
Fin/Fan Cooler - Equipment Summery Sheet
Heater Equipment Summery Sheet
API 650/629 Tank Equipment Summery Sheet
RISK MATRIX (VELOSI)
RISK MATRIC (API RBI)
Risk Ranking Summery Inspection History & Analysis
Plant Inspection Requirements
Replacements & Failures Reporting
Leaks & Defects
21. AD-HOC REPORTS (USER DEFINED REPORTS)
User can query the data as per desire & export to *.xls format files. Query might be SAVED for
future use.
22. REFERENCE LIBRARIES
System has the feature of adding the Reference Doc. Library i.e. SOPs
Operating Manuals
Drawings
Piping & Instrumentation Diagrams
Process Flow Diagrams
GA Drawing
Isometrics
ARIMS
Corrosion Model
23. NORSOK M-506 CO2 CORROSION MODEL
NORSOK M-506 CO2 Corrosion Model is available with in system to calculate/Assess the corrosion
due to CO2.
24. INTEGRITY PARAMETERS TRENDS REPORTING
System has capability of reporting integrity parameters trends; graphical representation of following
parameters is a static feature of VAIL-Plant;
Leaks
Metal Loss
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Remnant Life
Defects
Replacements
Risk Level
Corrosion Rate
25. SYSTEM USERS & USER GROUPS
User Groups can be created and configured based on the Clients BUSINESS LOGIC
Groups naming is not a hard & fast rule with in the system, only concern is the
configuration
User can be created and configured according to their concerned groups
Normally naming convention for Inspection Management System USERS is INSPCTOR,
ENGINEER & MANAGER
Separate Role can be assigned to each system users based on the needs & can be assigned
to a particular USER Group.
Only system ADMINSTRATOR has the rights to CREATE, MODIFY,ENABLE/DISABLE, BLOCK or DELETE any user account
26. DATA RECORDING BUSINESS LOGIC
INSERT:
Inspector can flag to create a new record/Tag (STATUS: NEW)
Engineer will review that Record/Tag (STATUS: REVIEWED)
Manager have to Approve that particular record/Tag (STATUS:APPROVED)
UPDATE:
Inspector Can flag to modify the Record (STATUS: MODIFIED)
Inspection Engineer will review the MODIFIED Record (STAUS: REVIEWED)
Inspection Manager will approve that particular Record/TagDELETE:
Inspector will flag the Tag for Deletion (STATUS:DELETED)
Inspection Engineer will review the flagged Record/Tag (STATUS:REVIEWED)
Inspection Manager will approve the deletion of Record/Tag
INSPECTION RECORDING:
Inspector has the full rights to inspection recording to INSERT, DELETE & UPDATE
ADMINISTRATOR has the full ACCESS RIGHTS to the system
27. SOFTWARE REQUIREMENTS
VELOSI VAIL-Plant software licenses will be required to meet the projects deliverables. Velosi
software required to support the VAIL-Plant implementation will be provided under licensesagreement.
In addition to Velosi software VAIL-Plant, third party software and SAP operating platforms will
be required to successfully install, integrate and operate the Velosi solution. The details are given as
under;
Microsoft Operating System Windows 2000 or Xp that is needed even to operate SAP
Any web browser supported by SAP Web Application Server, if not previously installed
DotNet framework 3.5
Crystal Reports 10.x
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SynFusion 2.0
SQL Server 2005
Windows Installer 3.1
CLIENT may desire Microsoft Office Suite tools like Excel, Word, etc. based on the end
users needs.28. HARDWARE REQUIREMENTS
Minimum: 1.6 GHz CPU, 512 MB RAM, 1024x768 display, 5400 RPM hard disk, Pentium
processor or equivalent (Recommended)
Recommended: 2.6 GHz or higher CPU, 2 GB RAM, 1280x1024 display, 7200 RPM or higher hard
disk