Guide for Asset Integrity Managers - Dr. Zaid Fayyaz - E-Book

Guide for Asset Integrity Managers E-Book

Dr. Zaid Fayyaz

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Beschreibung

Asset Integrity Management (AIM) is a term used to describe the practice of managing an asset (power plant, oil rig, refinery, etc) to ensure its ability to perform its function effectively and efficiently is maintained. Well run AIM strategies ensure that the people, systems, processes and resources that enable an asset to deliver its function are in place over the life cycle of the asset, while simultaneously maintaining health and safety and environmental legislation. AIM applies to the entirety of an asset’s operation, from its design phase to its decommissioning and replacement.

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GuideforAssetIntegrityManagers

AComprehensiveGuidetoStrategies,PracticesandBenchmarking

BY

Dr.ZaidFayyaz

ISBN9789354583391©Dr.ZaidFayyaz2021PublishedinIndia2021byPencilAbrandofOnePointSixTechnologiesPvt.Ltd.123,BuildingJ2,ShramSevaPremises,WadalaTruckTerminal,Wadala(E)Mumbai400037,Maharashtra,[email protected]rvedworldwideNopartofthispublicationmaybereproduced,storedinorintroducedintoaretrievalsystem,ortransmitted,inanyform,orbyanymeans(electronic,mechanical,photocopying,recordingorotherwise),withoutthepriorwrittenpermissionofthePublisher.Anypersonwhocommitsanunauthorizedactinrelationtothispublicationcanbeliabletocriminalprosecutionandcivilclaimsfordamages.

DISCLAIMER:TheopinionsexpressedinthisbookarethoseoftheauthorsanddonotpurporttoreflecttheviewsofthePublisher.

Authorbiography

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Contents

GuideforAssetIntegrityManagers

GuideforAssetIntegrityManagers

GuideforAssetIntegrityManagers A ComprehensiveGuidetoStrategies,PracticesandBenchmarking Introduction  Asset IntegrityManagement(AIM)isatermusedtodescribethepracticeofmanaginganasset(powerplant,oilrig,refinery,etc)toensureitsabilitytoperformitsfunctioneffectivelyandefficientlyismaintained.WellrunAIMstrategiesensurethatthepeople,systems,processesandresourcesthatenableanassettodeliveritsfunctionareinplaceoverthelifecycleoftheasset,whilesimultaneouslymaintaininghealthandsafetyandenvironmentallegislation.AIMappliestotheentiretyofanasset’soperation,fromitsdesignphasetoits decommissioning andreplacement. The primaryindustrysectorservedbyAIMisupstreamoilandgas.Thisisowingtotheescalatingworldwidedemandforenergy,whichhasresultedintheoilandgassectorincreasinginvestmentintothisareatoextendtheoperationalservicelifeofexistingrigs.However,theAIMprocesscanbeimplementedforanyassetofhighvalue,includingoilrefineries,electricalpowergenerationplantsandchemicalprocessingplants. Drivers forassetmanagement If infrastructureassetsarenotdeliveredormadeavailableinthemostcosteffectivemanner,societywillbearunnecessarycostsandmaymakedecisionsitwouldnothavemadeotherwise,orsufferotheradverseconsequences.TheprincipaldriversthatleadtoadoptingandcontinueddevelopmentofAMpracticesaresociety’sdesiresfor: Improved governanceofandaccountabilityforitsessentialinfrastructure Enhanced servicemanagementandcustomersatisfaction Improved riskmanagement Improved financialefficiency Sustainable managementofassets,resourcesandtheenvironment. Know howtheorganisationisperforming–operationsperformancemanagement    Both operationalandorganisationalperformancearequitedistinctfromassetperformance.Forexample,anetworkmightbeinexcellentconditionandrunningatthelowestlifecyclecostbutcustomercallsarenotanswered,internalandexternalreportingdeadlinesarenotmetandstatutoryinformationisnotprovided. Most organisationshaveLoS,whichcan(confusingly)alsobecalledCustomerLoS,thatstatethedesiredperformancesintheseareas.TheseCustomerServiceLoSandReportingLoSmustbereflectedintheCustomerLoSandTechnicalLoSagreedforinclusionintheAMPandinthedaytodaymanagementpracticesfortheassets. Role ofAssetIntegrityEngineer Asset IntegrityEngineersfocusonensuringthatanassetwillperformitsdesiredfunctionoveritslifecycle.AconstantchallengeforAIMengineersistobalancethedesigning,maintenanceandreplacementofassetsthroughouttheirlifecycle,whileminimisingcoststobusinessintermsoffinance,timeandresources. AIM engineersarerequiredtoconductmanytasks,including: Implement condition andstructuralhealthmonitoring(CSM) Ensure inspectionintervalsarenotexceeded Perform risk-based inspection(RBI) Conduct lifeextensionstudies Perform fitness-for-service reviews Conduct failure investigation studies Monitor andensureproceduresaremaintainedandimplemented Participate inpreparationofcapitalandoperatingbudgetsforinspection Pipeline IntegrityManagement Pipelines areacrucialpartoftheenergydeliverysystem.The oilandgas industryanditssupplychaininvestheavilytoensurethatpipelinescontinuetomeettheneedsoftheenergyindustryworldwide. Pipeline integritymanagement(PIM) isthephilosophyofimplementingacradle-to-graveapproachofunderstandingandoperatingpipelinesinasafe,reliablemanner[3].Pipelineoperatorsneedapipelineintegritymanagementsolutionwhichisabletostoreandintegratecriticaldataaboutthepipelineroute,materials,facilities,operations,inspections,repairsandmodificationstoensureefficientthrough-lifeoperationalefficiency. Pipeline operatorsarerequiredtoabidebyregulationsthatrequireregularbaselineevaluationsofpipelinesinareaswherefailuresaremostlikelytooccurandresultinsignificantdetrimentalimpactonpublicsafetyortheenvironment. What doesassetintegritymeanfortheoilandgasindustry? Asset integrity,orassetintegritymanagementsystems(AIMS)isthetermforanasset’scapacitytoruneffectivelyandaccurately,whilstalsoprotectingthewellbeingofallpersonnelandequipmentwithwhichitinteracts–aswellasthemeasuresinplacetoassuretheasset’slifecycle.Assetintegrityappliestotheentiretyofanassetsoperation,fromitsdesignphasetoitsdecommissioningandreplacement. The constantbusinesschallengeforassetintegritymanagersishowtobalancethedesigning,maintenance,andreplacementofassetsthroughouttheirlifecyclewiththecoststobusiness–intermsoffinance,time,andresources.Atitsheart,itisthemanagingofthedegradationofassets. 6.1. Elementsofassetintegritymanagement Much oftheoilandgasindustry’sinfrastructureisnoweitherapproachingorageingfarpastitsoperationallifeexpectancy.Withthecostofreplacingassets,andtheresultantturnaroundtime,prohibitivelyhighforsomanyfacilities,assetintegrityisnowrivallingtermssuchasOPEXandAgileasthewatchwordonpeople’slips. Challenges suchasvesselinspection,whichisasignificantcontributingfactortoproductiondowntime,andcorrosionunderinsulation,afrequentcauseofsuddenshutdowns,areontherise–andtakingthesteptoemploynewsolutionsisbecominganecessityinmanysites,particularlythoseoffshore. 6.2. Thehumanelement Asset integrityisbuiltonabeliefthatthemajorityofpeoplewithinthecompanywilldothingsproperly,andhoweveroptimisticthatmaysound,mostofthetimemaintenance,inspection,anddatamanagementisconductedwiththebestofintentions.However,thingsareoftennotcompletedthoroughlyorinastimelyamanneraspossible.Simplesolutionslikemorefrequentinspectionswon’tnecessarilyscoopupeverymissedissue,norwillitengenderaspiritofenthusiasmifworkersareaskedtoincreasetheirinspectionwork,orimplicatedinfaultsthataremissed. Some signsthatthingsmaynotallbewellintheworldofassetintegritymanagementandinspectioncaninclude: Team membersfeellikeanyconcernstheyhaveabouthealthandsafetyorthestateofequipmentarenotbeingtakenseriously,leadingtoanenvironmentinwhichfaultsarenotevenreported Any changesmadetoassetintegrityplans,orevenbasicrunningofthefacility,onlyoccurafteralarge-scaleincident A lackofunderstandingaroundhowtofindrootcausesfromsimplefaultreports,oftenresultinginpeoplebeinglulledintoafalsesenseofsecurityandoverstatingtheleveltowhichthefacilityissafeandoperational There isarelianceontacitunderstanding,ratherthanatangibleandeasily-accessiblesetofrulessurroundingAIMandreportingfaults There isalowest-bidderattitudesurroundingmaintenancecontractors,andknowledgeofandenthusiasmforassetintegrityisn’tvaluedparticularlyhighly The veryrealresultofthissortofclimateisthatnothingreallyhappens.Assetintegrityremainsabarelytolerablenuisance–asortofroadblocktoproperwork,untilamajorincidentforcesacompanytoadapt,oftenatgreatcost. Plugging thegapsinassetintegritymanagementsystems Whilst therearemoreAIMsystemsonthemarketthanatanyotherpointinthepast,therearestillnoout-of-the-boxcatch-allsolutions.NoinspectionplanordatabasecandealwithalltheAIMissuesthatcanarise,butintegritysystemsarestillseenasseparatetotherestofoperations.Staffcanbeunwillingtotakeownershipoftheirresponsibilities,insteadseeingthesuiteofvariousAIMpackagesasanattemptbythecompanytopolicethem,ratherthananintegralpartoftheirrole. The gapsinAIMpackagesneedtobefilledwiththevigilanceoftheverypeopletheyaredesignedtoprotect,butanovelapproachmaybenecessarytoensurethismessageisheard. Why assetintegritymanagementisimportant Over thecourseof22minutesonJuly6th 1988,thePiperAlphaNorthSeaoilplatformleakedcondensedgasthatignitedandledtoanexplosionkilling167oftherig’s229workers.ThisdisasterisseenbymanyoftheformativemomentofmodernapproachestobothEH&SandAIMinoilandgas,notleastbecauseitledtoa£1billionsafetymeasureinvestmentfromeveryoffshoreoperator. The UKgovernmentthenfollowedupwithapublicinquirywhichcametofruitionin1990,andcontained106directionsonhowbettertoconductHS&EandAIMstrategiesinfuture–allofwhichwereacceptedbytheoilandgasindustry. So, nowthatwearelivingandworkinginanageofseriousAIMefforts,whichareasshouldpeoplebefocussingon? Constructing anAIMstrategy Based onresearchconductedbyOil&GasIQ,oilandgasoperatorsarenowengaginginprice-responsivestrategiesandtheoptimisationofexistingassets.IntheNorthSeainparticular,thesecompaniesarenowre-evaluatingtheirpracticesinordertomakeendsmeet.51percentofoilandgasprofessionalsarenowworkingoninstallationsover20yearsintotheirservicelives–withlessthanathirdworkingoninstallationsintheirfirstdecadeofservice. More thanhalfofassetintegrityprofessionalshavehadtheirbudgetscutandtheaveragechosenratingofthoseprofessionalsowncompaniesAIMratingwas5.4outoften.Only52percentthoughtthattheirjobloadwassustainablewithregardstomeetingtargetsandmaintainingsafety–andthemajorityonlyhadameagrebudgetoflessthan£250,000.Unsurprisingly,thetwogreatestissuesaccordingtothoseinassetintegrityaremanagingassetsinbudgetandtheageoftheassetsthemselves.Byfarthegreatestflawperceivedinoilandgascompaniesisthelackofcommunicationbetweendepartments,followedbyalackofsafetyculture.Worktobedone,indeed. RBI: risk-basedinspection With ageinginfrastructurefastbecomingoneoftheindustry’smajorconcerns,itismoreimportantthanevertomakesureaneffectivesystemofidentificationisinplace.MorethanhalfofthepipelinesintheUSareatleast50yearsold,with3,300leaks,includingthelargestinUSpipelinehistory,eightydeaths,andnearly400injuries,inthepastfiveyearsalone. Despiteitsoundingsomewhatobvious,managingintegrity,corrosion,anddamageislikescopingoutanicebergfromsomedistanceaway. For everyeasily-identifiablesymptomofcorrosionorassetinstability,therearedozensofhiddenissues:hydrogenattack,high-temperaturetempering,thermalfatigue,metallurgyissues,internalsystemcorrosion,andsoon–andwithoutdedicatedandexperiencedprofessionals,implementingdamagemitigationtechniquesisnexttoimpossible.Onceonehasidentifiedtheneedforthoroughinspection,thenextstepistoenactit. RBI, orrisk-basedinspectionisonesuchmethod–wherebyonemustbalanceriskreductionwiththeminimumamountofeffortrequiredtostreamlinetheprocessandfreeupmoretime.However,thereareanear-infinitenumberofwaysinwhichtocarryourmaintenance–andwithmanyrisks(suchascalibrationuncertaintyorequipmentaccessibility)quantificationissimplynotpossible.Therefore,eachcompanymustdecidehowfaralongthequantitative/qualitativescaleitsits;whether