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ASSET INTEGRITYASSET INTEGRITYMANAGEMENTEnsuring the Integrity, Safety and Reliability of Plant
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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
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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)
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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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