Integrity Management Software Solution Managing your daily activities.

S. Ruik Beyhaut Product Management ROSEN Integrity Solutions GmbH Lingen, Germany

Contents
Why does the industry need Asset Integrity Management? Why should we maintain our tanks? Maintenance Excellence Develop Inspection Methodology Case Study ROSENs 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 Mexico 1984 USA 1989 Texas City USA 2005 Alaska Pipeline USA 2006

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Why should we maintain our tanks ?

To ensure that physical assets continue to do what their users want them to do (to fulfill their intended functions) Reliability (no major HSE incident) Availability Cost effective (where should we spent the money) Structured working process (auditable) Dont create backlog

Cost associated with operating Tanks

$ 3 10 M $ 0.5 3 M $ 0.1 0.5 M $ 0.01 0.1 M 1. Catastrophic failures (reputation, clean-up) Avoid (1)(2) 2. Unplanned shutdowns (non-availability) 3. Planned shutdowns (cleaning, repair) 4. In-service maintenance & inspection (NDT)

Optimize (3) Minimize (4)

Four stages to Maintenance Excellence

Stage I FireFire -fighter Stage II Controller Stage III Innovator Stage IV ME

< 30% mhrs spent on PM < 80% schedule compliance Failure modes unknown Minimum Risk focus Absence of PM eqpt audits

30 - 50% mhrs spent on PM 80%-90% schedule compliance Failure modes inventory

50-70% mhrs spent on PM 90-95% schedule compliance Condition based maintenance techniques Formal PM audits and updates

> 80% mhrs spent on PM > 95% schedule compliance Focus on failure prevention PM based on failure mode and failure effects Disciplined planning & scheduling Formal KPIs Performance analysis & improvement

PMs viewed as filler work Major pieces of equipment classified and receive PM focus No performance measurement

Application of RBI/RCM techniques Operators & craftsmen jointly responsible for PM

Absence of equipment criticality classification

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

COST

PREVENTIVE MTCE. COSTS

Fire-fighting Firemode

Comfort mode

COST OF NONNONAVAILABILITY
PROD. LOSS + BREAKDOWN

NOT ENOUGH EFFORT

OPTIMUM

TOO MUCH EFFORT MAINTENANCE EFFORT

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Develop Inspection Methodology

The inspection methodology or scope should be specific for each tank: Design Product Potential failure mechanisms

Integrity Services: 1. 2. 3. 4. Inspection Services Engineering Services Consultancy Services Integrity Management Support Services

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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)
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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.
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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 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
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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 Standards Operations Policy Audit & Review

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Design/Construction Data

Integration of Pipeline, facilities physical properties.

Risk ReAssessment

Design / Construction Data HCA Identification

Rehabilitation Action Tracking

Asset Data & Integrity Management

Data Gathering

Immediate & Future Repair Prioritization Inspection Data Integration

Risk-based Prioritization

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Data Gathering

Systematic methodology & storage to support IM process

Design / Construction Data

Data Collection & Integration Data Alignment > 6800km of pipelines Data Analysis > 260 Tanks

Risk ReAssessment

HCA Identification

Rehabilitation Action Tracking

Asset Data & Integrity Management

Data Gathering

Immediate & Future Repair Prioritization Inspection Data Integration

Risk-based Prioritization

> 8000 documents

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Risk-based Prioritization

Identification & prioritization of risks to determine, how, where and when to allocate mitigation resources Tank Inspection prioritization
Risk ReAssessment

Design / Construction Data HCA Identification

Rehabilitation Action Tracking

Asset Data & Integrity Management

Data Gathering

Immediate & Future Repair Prioritization Inspection Data Integration

Risk-based Prioritization

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Risk-based Prioritization (ROSENs Tank RBI methodology )

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.

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.
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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) Tank Storage Istanbul RBI is a dynamic tool 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

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Rehabilitation Action Tracking

Follow up of repair actions including resource planning and NDT comparison, GIS update activities Budget planning and track the status of field activities Coordinate tasks on the basis of both risk and maintenance based tasks
Risk ReAssessment

Design / Construction Data HCA Identification

Rehabilitation Action Tracking

Asset Data & Integrity Management

Data Gathering

Immediate & Future Repair Prioritization Inspection Data Integration

Risk-based Prioritization

Tank Storage Istanbul 3 & 4 November 2010, GCH Convention Centre

Conclusion Turn Key Management Solution:

Development Phase

Acceptance Phase

Support

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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

Enjoy the Conference