ensuring the integrity, safety and reliability of · pdf fileensuring the integrity, safety...

ASSET INTEGRITYASSET INTEGRITYMANAGEMENTEnsuring the Integrity, Safety and Reliability of Plant

OBJECTIVES OF ASSET OWNERSOBJECTIVES OF ASSET OWNERS

Regulatory Compliance

Maximise production

Reduce lost income due to unplanned shutdowns

Optimise inspection & maintenance p pcosts

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ASSET INTEGRITY MANAGEMENTASSET INTEGRITY MANAGEMENT

To maintain the asset in a fit-for-service condition while extending its remaining life incondition while extending its remaining life in a the most reliable, safe and cost effective manner

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MANAGEMENT COMMITMENTMANAGEMENT COMMITMENT FROM DESIGN THROUGH TO OPERATION

ProcurementDesign

ConstructionOperation

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SGS AIM SUMMIT- NOV 2013

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SGS AIM SUMMIT-A PLATFORM TO DISCUSS INDUSTRIAL ASSETS PROBLEMS

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ASSET LIFE CYCLEASSET LIFE CYCLE

D i R i f Vendors AuditDesign Review for

Engineering & Safety

Vendors Audit

QA of Equipment

d i f tProcurment

Design

Codes during manufacture

Engineering/Construction

Operation Documented QA PlanRisk Assessment Construction Documented QA Plan,

Inspection/testing and

Dossier of records

Risk Assessment,

Monitoring &

Mi i i Dossier of recordsMitigation

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HISTORYHISTORY

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RISK BASED INSPECTION

A systematic approach to identify the potential degradation h i d h h i i f h i dmechanisms and threats to the integrity of the equipment and to

assess the consequences and risks of failure

Risk = Probability x Consequence

High

Medium-High

MediumRisk Ranking

Low

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RBI WORK FLOW

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OUTCOME OF RBIRisk Matrix of Equipment

Inspection strategyWHAT – The equipment that needs to be inspected

WHERE – The location of Inspection

WHEN – The optimum interval between inspectionWHEN The optimum interval between inspection

HOW – Specify the right technique to detect the defects that aparticular component is most likely to develop.

HOW MUCH – The coverage (extent) of inspection.

Operating Window

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Operating Window

ADVANCED & NON-INTRUSIVE INSPECTION TECHNIQUESINSPECTION TECHNIQUES

Time of Flight Diffraction [TOFD]Phased Array weld InspectionPhased Array weld InspectionGuided Wave Long Range Ultrasonic, LRUTMagnetic Flux Leakage testing of tank bottom[MFL]Magnetic Flux Leakage testing of tank bottom[MFL]ThermographyTubing Inspection, EC, IRIS, RFT, MFLTubing Inspection, EC, IRIS, RFT, MFLVideoscopy with sizing capabilityAutomated UT weld scanning & Corrosion Mapping g pp gCHIME, rapid non invasive Scanning of pressure vessels Automated UT Crawler for tank shell UT monitoringFlange Face Phased Array scanningField Metallography

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PMI (Positive Material identification)

ADVANCED & NON-INTRUSIVE INSPECTION TECHNIQUESTECHNIQUES

Guided Wave Long Range UltrasonicPipeline Screening for corrosion spotsPipeline Screening for corrosion spots

Phased Array weld Inspectiony pWeld inspection -New-construction & in-service

Time of Flight Diffraction [TOFD]Weld inspection

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ThermographyHeat losses

Tubing Inspection, EC, IRIS, RFT, MFLHeat-Exchanger

Videoscopy with sizing capabilityEngines, turbines, pipes, nozzles, vessels, etc.CHIMEInaccessible areasInaccessible areasclamps and saddlespipe supports tank floorspipe supports, tank floorshalf buried pipes.

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Flange Face Phased Array scanningboth flange seal face surfaces simultaneouslyboth flange seal face surfaces simultaneously

Field Metallographymicro structural changes in a component.

Magnetic Flux Leakage (MFL) testingt k b tt d id i it itank bottoms under side corrosion monitoring.

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DATA MANAGEMENTProject PerformanceIndicatorsShutdown & Maintenance

D t ti

Corrosion Monitoring Inspection

Tracking & Reporting Systems

Tags PSV’s RMS

Documentation

Monitoring Inspection Data

Mechanical & ProcessD

Tags PSV s RMS, Rotating & Static,PipelinesLifting EQ .HSE??Data

EquipmentDocumentation

Lifting EQ .HSE

Corrosion Monitoring,Next inspection,

Remaining Life? ?

Regulatory Documentation

Documentation Remaining Life

Inspection and MaintenanceInspection and MaintenancePlanningPlanning

Local & Global ReportingCAD & Inspection IsometricsDrawings

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ONE WINDOW SOLUTION Risk BasedInspection Recommendations

Technical / DesignDatasheets

Condition Alerts

Operating Envelopes/ CP Alert

Thickness MonitoringInspection Management / CP Alert

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SGS CAN ASSIST

Risk Based Inspection Services

Inspection Program ExecutionCertified Engineers & Inspectors -API, NDT, ASME, NACEPool of conventional & advanced NDT techniquesPool of conventional & advanced NDT techniquesData evaluation, recommendation and FFS assessment.

Inspection Data ManagementInspection Data ManagementTrend Monitoring and Inspection work generation

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