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Integrity Management Software SolutionManaging your daily activities.
S. Ruik BeyhautProduct Management ROSEN Integrity Solutions GmbHLingen, Germany
Contents
• Why does the industry need Asset Integrity Management?
• Why should we maintain ‘our’ tanks?
• Maintenance Excellence
• Develop Inspection Methodology
• Case Study
• ROSEN’s Tank RBI methodology
• Conclusion
Why does the industry need Asset Integrity Management?
To avoid and mitigate against major accidents or incidents, by ensuring major accident barriers are in place and are rigorously maintained. With an ageing asset infrastructure there is a requirement for effective process safety management, and major hazard risk controls to be in place.
•Washington, 2002
•Flixborourgh UK 1974
•UK 1988•UK 1988
•Mexico 1984
•USA 1989
•Texas City USA 2005
•Alaska Pipeline USA 2006
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Why should we maintain ‘our’ tanks ?
• Reliability (no major HSE incident)
• Availability
• Cost effective (where should we spent the money)
• Structured working process (auditable)
• Don’t create backlog
To ensure that physical assets continue to do what their users want them to do (to fulfill their intended functions)(to fulfill their intended functions)
• 1. Catastrophic failures (reputation, clean-up)$ 3 –10 M
• 2. Unplanned shutdowns (non-availability) $ 0.5 – 3 M
• 3. Planned shutdowns (cleaning, repair)$ 0.1 – 0.5 M
• 4. In-service maintenance & inspection (NDT)$ 0.01 – 0.1 M
Avoid (1)(2)
Optimize (3)
Minimize (4)
Cost associated with operating Tanks
Four stages to Maintenance Excellence
< 30% mhrs spent on PM
< 80% schedule compliance
Failure modes unknown
30 - 50% mhrs spent on PM
80%-90% schedule compliance
50-70% mhrs spent on PM
90-95% schedule compliance
> 80% mhrs spent on PM
> 95% schedule compliance
StageStage IIFireFire--fighterfighter
StageStage IIIIIIInnovatorInnovator
StageStage IVIV
MEME
StageStage IIIIControllerController
Failure modes unknown
Minimum Risk focus
Absence of PM eqpt audits
Absence of equipment criticality classification
Failure modes inventory
PM’s viewed as filler work
Major pieces of equipment classified and receive PM focus
No performance measurement
Condition based maintenance techniques
Formal PM audits and updates
Application of RBI/RCM techniques
Operators & craftsmen jointly responsible for PM
Focus on failure prevention
PM based on failure mode and failure effects
Disciplined planning & scheduling
Formal KPIs Performance analysis & improvement
• So we must aim for the best of the best
• Risk is not gambling
• Compliance is a key
• No doubt your performance will fit in different sections
• HW the aim and direction of focus is clear
Cost Effectiveness of Maintenance
CO
ST
FireFire--fightingfighting
modemode
ComfortComfort
modemode
PREVENTIVE PREVENTIVE
MTCE. COSTSMTCE. COSTS
MAINTENANCE EFFORT
NOT ENOUGH EFFORTNOT ENOUGH EFFORTNOT ENOUGH EFFORTNOT ENOUGH EFFORT OPTIMUMOPTIMUMOPTIMUMOPTIMUM TOO MUCH EFFORTTOO MUCH EFFORTTOO MUCH EFFORTTOO MUCH EFFORT
modemode modemode
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
COST OF NONCOST OF NON--
AVAILABILITYAVAILABILITYPROD. LOSS + BREAKDOWNPROD. LOSS + BREAKDOWN
Develop Inspection Methodology
The inspection methodology or scope should be specific for each tank:
• Design
• Product
• Potential failure mechanisms
Integrity Services:Integrity Services:
1. Inspection Services
2. Engineering Services
3. Consultancy Services
4. Integrity Management Support Services
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
1. Inspection Services
• MFL Floor scanning (incl. repair plan)
• Shell thickness measurements
• API / EEMUA Inspections / NDT services (MT, PT, UT, LT)
2. Engineering Services
• Compliance checks (API653 / EEMUA159 / National)
• Repair advise, detailed eng.. (e.g. modifications, new tank(s))
3. Consultancy Services
• Training & Workshops
• V.O.C. Emission control
• Development of procedures or guidelines
4. Integrity Management Support
• Tools for upgrading your Tank Integrity Management System
• Tank prioritization program (MRP “health check”)
• Asset Management Database & Tank RBI (ROAIMS)Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
ROAIMS for Tanks
The streamlined software design and its comprehensive database offers a range of user-friendly modules:
• simplifying data organization and management
• supporting task planning/scheduling
• moving from time based to condition based (preventive maintenance)
• provide tailored reporting capabilities
to meet both internal and external requirements.Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Case Study– General Overview
ECOPETROL S.A., biggest state-run pipeline operator in Colombia implemented the project “The purchase of an IT tool to support & manage Pipeline and Tank Integrity”.
• Implementation & Customization of a Pipeline
& Tank Integrity Management Software
• Risk Assessment of its Pipelines• Risk Assessment of its Pipelines
• Set up a Risk Based Inspection Plan
for its Storage Tanks
• Software tools for Quality Assurance/Quality
Control of the individual processes
• Centralized database for increasing knowledge about condition and reliability of its assets
Overall goal: Supporting tool to develop prioritization and repair plans
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Project Scope – Data Overview
• Total Length of pipeline network: 6800 km (different diameters)
• Total Tanks: 260 spread all over the country
• Different sizes from 10 mts to 60 mts diameter
• Mechanical data, tank inspections and other important data were available in printed version and excel sheets.
• Integration of External Inspection results (CP, DCVG, CIS, Soil Resistivity,……)
• Consecutive ILI runs available ( 50+ ILI runs, various vendors)
Codes, Standards & Legislations
HSE
Policy
Legislative
Requirements
Integrity Performance
Operations
Policy
Audit & Review
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Policy RequirementsPerformance
Standards Policy Review
Design/Construction Data
Asset
Data &
Design / Construction
Data
HCA Identification
Rehabilitation
Risk Re-Assessment
Integration of Pipeline, facilities
physical properties.
Data & Integrity
Management
Data Gathering
Risk-based Prioritization
Inspection Data
Integration
Immediate & Future Repair Prioritization
Rehabilitation Action
Tracking
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Data Gathering
Asset
Data &
Design / Construction
Data
HCA Identification
Rehabilitation
Risk Re-Assessment
Systematic methodology & storage to support IM process
•Data Collection & Integration
•Data Alignment > 6800km of pipelines
•Data Analysis > 260 Tanks
Data & Integrity
Management
Data Gathering
Risk-based Prioritization
Inspection Data
Integration
Immediate & Future Repair Prioritization
Rehabilitation Action
Tracking
> 8000 documentsTank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Risk-based Prioritization
Asset
Data &
Design / Construction
Data
HCA Identification
Rehabilitation
Risk Re-Assessment
Identification & prioritization of risks to determine, how, where and when to allocate mitigation resources
•Tank Inspection prioritization
Data & Integrity
Management
Data Gathering
Risk-based Prioritization
Inspection Data
Integration
Immediate & Future Repair Prioritization
Rehabilitation Action
Tracking
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
• Complies with the API requirements for applying RBI
• Final deliverable is an inspection plan for tank & its sub-components, with details of activities related to the current operation from a S/H/E/E standpoint.
• For risks considered unacceptable, the plan contains the mitigation actions, scope and timing of inspection/examination recommended.
Risk-based Prioritization (ROSEN’s Tank RBI methodology )
RBI Benefits and Limitations
• This RBI plans also identify equipment which does not require inspection
• An important decrease on the amount of inspection data that is collected
• ”Rubbish in, is Rubbish out”. RBI will not compensate inaccurate or missing information, inadequate designs equipment installation, operating outside acceptable design envelope, not effectively executing the plans in a timely manner, lack of qualified personnel or teamwork, and lack of sound engineering judgment.
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Project Framework for RBI implementation (Tanks)
• Approach of Implementation, based on API 580.
• The core of a RBI assessment: team-based process.
• Identification of the appropriate deterioration mechanisms, failure modes for all tank components, which had an effect on the quality & effectiveness of the RBI
• Risk model customized, regional peculiarities ( e.g. Company image/Reputation)
• RBI is a dynamic tool Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Risk-based Achievements (Tanks)
• Optimize routine operation on basis of condition
• Reduce out-of-service time (non-availability cost)
• Spread maintenance and inspection effort
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
•Budget planning and track the status
of field activities
Rehabilitation Action Tracking
Asset
Data &
Design / Construction
Data
HCA Identification
Rehabilitation
Risk Re-Assessment
Follow up of repair actions including resource planning and NDT comparison, GIS update activities
•Coordinate tasks on the basis of both
risk and maintenance based tasks
Data & Integrity
Management
Data Gathering
Risk-based Prioritization
Inspection Data
Integration
Immediate & Future Repair Prioritization
Rehabilitation Action
Tracking
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Turn Key Management Solution:
Conclusion
Development Phase SupportAcceptance Phase
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre
Conclusion
Overall project implementation :
• High quality and transparency of information via central database
• Central Intelligence Center keeps track of actions in branches
• Permanent Trainings and involvement during project ensures ability to self-operate
• Delivery is used as master source for future maintenance budget planning
• After 18 months of intense development, testing and good teamwork the system was implemented at ECOPETROL and the corresponding admin and user training delivered.
Overall benefits of Tank RBI implementation :
• Structured approach of Maintenance & Inspection activities
• Justification process for preventive Maintenance &Inspection budgeting
• Loop based process (based on experiences and evidence)
• Development of proactive Maintenance &Inspection tasks
• Focus on critical tank (sub-) components
• Reduce out-of-service period
• Increase availability & reliability
• Better scope of work (and $) definition prior O.O.S. (out-of-service)
• Engineering experience, training, codes and so further, together with a sophisticated software solution are the key to success when comes to implementing an Asset Integrity Management into a Storage Tank Operator.
Tank Storage Istanbul
3 & 4 November 2010, GCH Convention Centre