Risk Based Inspection: Dynamic Optimisation of Inspection Plans

Risk Based Inspection
part of Aker
Dynamic optimisation of inspection plans

ystein Bjaanes, Manager AIM Competence Centres
2011 Aker Solutions
Content
Aker Solutions in brief Who we are and what we do
Dynamic optimisation of inspection plans / integrated planning
Non-Intrusive Inspection a significant contribution to optimisation
February 2011
Slide 2
2011 Aker Solutions
part of Aker
part of Aker
Who we are and

what we do
Aker Solutions
January 2012
2011 Aker Solutions
Aker Solutions in brief

A leading global provider
Operating
revenues
of engineering and
technology, products and
service solutions to the oil
and gas industry
Employees: 18 000
Contract staff: 4 600

Operations in 30 countries
NOK 33.4 bn
Operating
profit (EBITDA)
NOK 3.3 bn
Market
capitalisation
NOK 18.3 bn
11th largest
on OBX index
Revenues and profits are for 2010

Market value as of 04.11.2011
In Brief
Slide 4
2011 Aker Solutions
part of Aker
Our vision and values

Built on more than 170 years of industrial tradition
Our vision
is to be "The preferred partner
for solutions in the oil and gas industry" through living ...
Our values
Customer
drive
Building
customer
trust is key to
our business
HSE
mindset
People
and teams
We take personal
responsibility for
HSE because
we care
All our major

achievements
are team
efforts
Open and
direct
dialogue
We encourage
early and honest
communication
Hands-on
management
We know our
business and get
things done
Delivering
results
We deliver
consistently and
strive to beat
our goals
In Brief
Slide 5
2011 Aker Solutions
part of Aker
Aker Solutions main offerings

Field-life solutions
Engineering solutions
Maintenance,
Modifications &
Operations specialist
who help oil companies
reduce operating costs
and extend life-of-field.
Engineering provides
full field development
understanding, front-end
design and conceptual
engineering
Product solutions
Umbilicals Static and
dynamic umbilicals
and subsea power
cable systems for the
oil and gas sector
Drilling technologies
incl. full range of drilling
equipment, drilling riser
solutions and related
products.
Subsea production
systems and lifecycle
services, wellheads,
controls, manifolds and
tie-in systems
Process systems
technologies within
water injection, gas
processing
conventional and heavy
oil treatment, produced
water and sand
handling and others.
Mooring and loading

systems supply design,
engineering and supply of
innovative deck
machinery.
Well intervention
services incl. wireline,
wireline tractor,
logging, light well
intervention etc.
Oilfield Services &
Marine Assets offers
deepwater well
intervention services and
subsea construction.
Slide 9
In
Slide
Brief
9
2011 Aker Solutions
part of Aker
Aker Solutions Asset Integrity Management (AIM)

...is differentiated by providing AIM services from well to shore
throughout the entire life cycle
Maintenance
programme &
budget
OPEX
Maintenance
Planning
Maintenance
Philosophy
& Strategy
Maintenance & Inspection
Engineering
Technical Integrity
analysis & studies
Structural Integrity
Management
Subsea Integrity
Management
Execution
Analysis &
Improvement
Inspection &
Monitoring
Data base
CAPEX
Advanced Inspection &

Monitoring Technology
In-Service Inspection &

Corrosion Management
Fabrication & Weld

Inspection (NDT)
Data Management,
Systems & Tools
CC
I I
Design Integrity
Asset Integrity Management Services

Maintenance frame agreement contractor
2011 Aker Solutions
part of Aker
Content
February 2011
Slide 11
2011 Aker Solutions
part of Aker
Bakgrunn - Aktivitetsforskriften
45
Vedlikehold
Den ansvarlige skal sikre at innretninger eller deler av disse holdes ved like, slik at de er i stand til utfre sine tiltenkte
funksjoner i alle faser av levetiden.
46
Klassifisering
Innretningers systemer og utstyr skal klassifiseres med hensyn til konsekvensene for helse, milj og sikkerhet av potensielle
funksjonsfeil.
For funksjonsfeil som kan fre til alvorlige konsekvenser, skal den ansvarlige identifisere de ulike feilmodiene med
tilhrende feilrsaker og feilmekanismer, og ansl feilsannsynligheten for den enkelte feilmodusen.
Klassifiseringen skal legges til grunn ved valg av vedlikeholdsaktiviteter og vedlikeholdsfrekvens, ved prioritering av ulike
vedlikeholdsaktiviteter og ved vurdering av reservedelsbehov.
47
Vedlikeholdsprogram
Feilmodi som utgjr en helse-, milj- eller sikkerhetsrisiko, jf. 44, skal forebygges systematisk ved hjelp av et
vedlikeholdsprogram.
I programmet skal det inng aktiviteter for overvking av ytelse og teknisk tilstand, som sikrer at feilmodi som er under
utvikling eller har inntrdt, blir identifisert og korrigert.
Programmet skal ogs inneholde aktiviteter for overvking og kontroll av feilmekanismer som kan fre til slike feilmodi.
48
Planlegging og prioritering
Det skal utarbeides en samlet plan for utfring av vedlikeholdsprogram og korrigerende vedlikeholdsaktiviteter, jf.
styringsforskriften 12.
Det skal foreligge kriterier for setting av prioritet med tilhrende tidsfrister for utfring av de enkelte vedlikeholdsaktivitetene.
Kriteriene skal ta hensyn til klassifiseringen som nevnt i 46.
February 2011
Slide 12
2011 Aker Solutions
part of Aker
Bakgrunn Vedlikeholdsstyringsslyfa,
Ref. Basisstudien, OD1998
February 2011
Slide 13
2011 Aker Solutions
part of Aker
Risk Based Inspection Framework:

RBI in accordance with DNV RP-G101 and
API580/581
Start
Scope
Development
Secure optimum availability at acceptable

risk
Team
selection
o
o
Prioritize inspection efforts on the items

driving the risk
Integrity / inspection philosophy

risk matrix definition
Documents and
mechanical
data
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Estimate PoF & CoF

according to risk matrix
definition
Level 2 RBI
assessment
Level 3 RBI assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Upload to
CMMS &
CIMS
Document the evaluation leading to

definition of inspection and condition
monitoring programs
Can be used to inform relevant stake
holders, e.g. governments, owners,
management, technicians
An inspection framework based on RBI,
and formalized through implementation of
RBI and inspection management software,
as well as computerized maintenance
management system, gives a holistic view
and is a powerful tool, for management
and reporting of asset technical condition
End
February 2011
Slide 14
2011 Aker Solutions
part of Aker
RBI work process: Scope development,

agreement of procedures and team
definition
Start
Scope
Development
Scope in detail: Items to be included, as

well as detailed deliverables
Team
selection
o
o
RBI Team to include correct competence

and experience:

Documents and
mechanical
data
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Project management
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Yes
Risk level /
inspection plan
OK?
No
PoF
assessment
Safety risk analysis

Process and operation of the plant
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Materials and corrosion
CoF
assessment
NDT and inspection planning

Field inspection
Detailed
inspection
planning
Yes
Risk level /
inspection plan
OK?
Maintenance
No
Review
engineering of
item
Upload to
CMMS &
CIMS
CMMS and database management
End
February 2011
Slide 15
2011 Aker Solutions
part of Aker
RBI work process: Data collection Documents and mechanical data:
Start
General data (e.g. system definitions, area

definitions, material specifications,
insulation specification, coating codes, risk
matrix, company specific philosophies etc.)
Scope
Development
Team
selection
o
o

Equipment specific data (e.g. equipment

design parameters for temperature and
pressure, dimensions, materials, coatings,
insulation, product codes, location etc.)
Documents and
mechanical
data
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Upload to
CMMS &
CIMS
End
February 2011
Slide 16
2011 Aker Solutions
part of Aker
Example risk matrices:

Refer API 581:
Start
Scope
Development
Team
selection
o
o

Documents and
mechanical
data
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Example - Fit to specific customer:

PoF Cat
up to
1
1,00E-01
1,00E-02
1,00E-03
1,00E-04
Cat
5
4
3
2
1
A
M
M
L
L
L
CoF
B
H
M
M
L
L
Category
C
D
H
H
H
H
M
H
M
M
L
M
Upload to
CMMS &
CIMS
End
February 2011
Slide 17
2011 Aker Solutions
part of Aker
E
H
H
H
H
M
RBI work process: RBI Screening:

High level evaluation to identify hazards
and assign each equipment tag to an
integrity strategy
Start
Scope
Development
Team
selection
o
o

Condition monitoring
Documents and
mechanical
data
Detailed RBI (sign. PoF and CoF)
RBI
Screening
workshop
(insign. PoF, but sign. CoF)
Planned corrective maintenance

(significant PoF, but insignificant CoF)
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Corrective maintenance (insign. PoF and CoF)

Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Upload to
CMMS &
CIMS
PoF Probability of Failure
End
CoF Consequence of Failure
February 2011
Slide 18
2011 Aker Solutions
part of Aker
RBI work process: Detailed RBI / level 2

Semi-quantitative RBI analysis. Level of
quantification to be agreed with customer
Start
Scope
Development
Assessments performed on equipment /

corrosion circuit using available information,
e.g. actual process conditions, operational
history, inspection history and findings
Team
selection
o
o

Documents and
mechanical
data
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Upload to
CMMS &
CIMS
End
February 2011
Slide 19
2011 Aker Solutions
part of Aker
RBI work process: Level 3 RBI

assessment
Start
Where the detailed RBI indicates

unacceptably high risk or unacceptably
frequent inspection, a detailed study of the
risk drivers is carried out
Scope
Development
Team
selection
o
o

Recommendation of mitigating actions,

e.g. equipment modifications, process
changes, operational changes
Documents and
mechanical
data
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Upload to
CMMS &
CIMS
End
February 2011
Slide 20
2011 Aker Solutions
part of Aker
RBI work process: Inspection planning and

implementation in CMMS
Start
Detailed inspection planning providing details

on inspection intervals and time for
inspection, inspection method, areas for
inspection (including inspection drawings),
how it shall be reported etc.
Scope
Development
Team
selection
o
o

Documents and
mechanical
data
Inspection activities should be planned

together with other maintenance activities
where these have dependencies
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Required procedures and work task

descriptions
Monitor for
PoF drivers
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Upload to
CMMS &
CIMS
End
February 2011
Slide 21
2011 Aker Solutions
part of Aker
RBI work process: Condition monitoring

program
Start
Establish integrity operating envelopes in

order to verify validity of RBI analysis and
check PoF drivers against pre-defined limits
Scope
Development
Team
selection
o
o
Define monitoring parameters on instrument

tag level / test points etc.

Documents and
mechanical
data
Monitoring to be focused on significant

influence factors, e.g:
RBI
Screening
workshop
Insignificant
Significant
Screening
probability
level
Planned
Corrective
maintenance
Screening
consequence
level
Insignificant
Corrective
maintenance
Significant
Significant
Screening
probability
level
Insignificant
Documents
& data for
RBI
Monitor for
PoF drivers
Estimate PoF & CoF

definition
Level 2 RBI
assessment
Yes
Detailed
inspection
planning
Risk level /
inspection plan
OK?
No
Yes
PoF
assessment
CoF
assessment
Risk level /
inspection plan
OK?
No
Review
engineering of
item
Corrosion / erosion probes; e.g. erosion

coupons, corrosion coupons, bacteria
coupons
Vibrations / stress monitoring
Process parameters; e.g. pressure,
temperature, velocity, pH, oxygen
content, fluid conductivity, CO2, H2S etc.
Performance parameters; e.g. heat
transfer, pressure drop, chemical
injection pump availability
Upload to
CMMS &
CIMS
End
February 2011
Slide 22
2011 Aker Solutions
part of Aker
Cost-benefits of process- and condition monitoring for

static mechanical process equipment: a case study
It is recognized that heat recovery units (HRSG) systems have
experienced significant problems due to leaks from water / steam

piping and heat exchangers.
Main degradation mechanism have been stress corrosion cracking
and corrosion fatigue in stainless steel pipes (SS316 / SS321) and

flow assisted corrosion in carbon steel pipes.
February
Date
Month
2011
2011
Slide 23
2011 Aker Solutions
part of Aker
Cost-benefits of process- and condition monitoring for

static mechanical process equipment: a case study (cont)
It has been recognized that monitoring of significant influence
factors (conductivity, pH, oxygen content, nitrite content) and

acting on out of spec parameters could have prevented leaks
Leaks and shutdown of steam loops implicates that electricity has
to be generated from gas driven generator

Calculations from one installation offshore Norway indicates an
extra cost of $ 13-17 mill per year due to lost heat generation, as
well as $ 35-50 mill in modification costs
February
Date
Month
2011
2011
Slide 24
2011 Aker Solutions
part of Aker
Content
February 2011
Slide 25
2011 Aker Solutions
part of Aker
Strategise
CMMS
AMST
RBI
Slide 26
RCM
FMECA
SRCM
RAMS
LCC
MTTF
PF
CRL
Spares
Failure Analysis
2011 Aker Solutions
part of Aker
Monitor Static Equipment

Infrared Camera
Ultrasonics
Desicion
Support
Exceptions
CMMS
Inspector
Inspector S-Pro
I.S. Data Collector
CMDM 5660
Inspections
Ultrasonics
Radiography
Strain
Visual
Vibration
Acoustics
Corrosion
Process
AMST
RBI
Slide 27
RCM
FMECA
SRCM
RAMS
LCC
MTTF
PF
CRL
Spares
Failure Analysis
2011 Aker Solutions
part of Aker
Monitor Rotating
Off-line
Desicion
Support
Protection
Exceptions
CMMS
Analyst
AMST
RBI
Slide 28
RCM
FMECA
SRCM
RAMS
LCC
MTTF
PF
CRL
Spares
Failure Analysis
Vibration
Lube Oil
Performance
Strain
Electrical
Balance
Alignment
Bearing Inspection
2011 Aker Solutions
On-line
Wireless
part of Aker
Reporting
Planning
OPC
OPC
Results Reporter
Static
RCFA
Desicion
Support
Rotating
Client Meeting
Planning Board
RCA
Desicion
Support
Exceptions
Exceptions
CMMS
Slide 29
2011 Aker Solutions
part of Aker
DCS
Dashboard
(supervisory control and data acquisition)
(distributed controls system)
Smart Signal
Pi
To @
SCADA
To @
Integrasjon Router
OPC
OPC
Slide 30
2011 Aker Solutions
part of Aker
Dashboard
DCS
SCADA
(supervisory control and data acquisition)
(distributed controls system)
Smart Signal
Pi
Integration Router
Infrared
OPC
Off-line
OPC
Results Reporter
Static
RCFA
Desicion
Support
Eddy Current Inspection
of tube stack
Client Meeting
RCA
Planning Board
Inspections
Ultrasonics
Radiography
Strain
Visual
Vibration
Acoustics
Corrosion
Process
Thermography
Ultrasonics
Slide 31
Desicion
Support
Protection
Exceptions
Exceptions
Inspector
Inspector S-Pro
I.S. Data Collector
CMDM 5660
Rotating
CMMS
Analyst
AMST
RBI
RCM
FMECA
SRCM
RAMS
LCC
MTTF
PF
CRL
Spares 2011 Aker Solutions
Failure Analysis
On-line
Vibration
Lube Oil
Performance
Strain
Electrical
Balance
Alignment
Bearing Inspection
Wireless
part of Aker
Content
February 2011
Slide 32
2011 Aker Solutions
part of Aker
Non-Intrusive inspection (NII)

Where the RBI identifies internal degradation mechanisms which can be
followed up through periodic inspection, it should be evaluated whether

inspection can be performed non-intrusively
Non-Intrusive Inspection means inspection from outside, without breaking
the integrity. Performed during production (or during shut down)

Assessment can be performed in accordance with DNV RP-G103, Non-
Intrusive Inspection
AkerSolutions have developed a NII screening methodology considering
Technical issues (design / construction data, inspection history etc)

HSE issues
Business issues (cost benefit evaluations)
Why NII?
Reduce need for entering of confined space (safety of personnel)

Increase production availability
More flexibility in planning of shut down work
NII assessment capabilities will be implemented in AkerSolutions RBI and
inspection management software

February 2011
Slide 33
2011 Aker Solutions
part of Aker
Cost-benefits of Non-Intrusive Inspection: a case study

Item
Electrostatic coalescer, tag No. XXXX-VJ20001A
Presumptions
and
experience
Entering tank for IVI will be done outside revision stop, while
producing through parallel coalescer

In order to secure acceptable water in oil content, the
production is reduced by 3-5000 barrels per day for about 20

days
Evaluation
IVI implicates an accumulated deferred production of $ 5-10
mill while NII does not affect the production

The inspection cost for IVI and NII is about the same ($ 0.22
vs. 0.18 mill)

Manpower required for IVI and NII is about the same (4 vs. 5
persons, about 20 days)

The risk related to entering the tank is significant wrt.
personnel, and redundancy is lost while performing IVI. Risk

related to NII is low
:
:
.
Conclusion
February
Date
Month
2011
2011
There is a potential for significant savings, both in terms of risk

and production, by implementing NII
Slide 34
2011 Aker Solutions
part of Aker

Dynamic optimisation of inspection plans
Extend service life and verify safe operation of an asset
by a combination of analysis, monitoring and inspection

A systematic use of available process- and condition
monitoring data, available technology and Non-Intrusive
Inspection in order to give better production availability
while securing acceptable risk
Use integrated planning as a tool to dynamically optimise
maintenance- and inspection plans
February 2011
Slide 35
2011 Aker Solutions
part of Aker
Copyright
Copyright of all published material including photographs, drawings and images in this document remains vested in
Aker Solutions and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document
shall be reproduced in any form nor used in any manner without express prior permission and applicable
acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.
Disclaimer
This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to
risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on
current expectations, estimates and projections about global economic conditions, the economic conditions of the
regions and industries that are major markets for Aker Solutions ASA and Aker Solutions ASAs (including subsidiaries
and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements
containing words such as expects, believes, estimates or similar expressions. Important factors that could cause
actual results to differ materially from those expectations include, among others, economic and market conditions in
the geographic areas and industries that are or will be major markets for Aker Solutions businesses, oil prices, market
acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency
exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Aker
Solutions ASA believes that its expectations and the Presentation are based upon reasonable assumptions, it can give
no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation.
Aker Solutions ASA is making no representation or warranty, expressed or implied, as to the accuracy, reliability or
completeness of the Presentation, and neither Aker Solutions ASA nor any of its directors, officers or employees will
have any liability to you or any other persons resulting from your use.
Aker Solutions consists of many legally independent entities, constituting their own separate identities. Aker Solutions
is used as the common brand or trade mark for most of these entities. In this presentation we may sometimes use
Aker Solutions, we or us when we refer to Aker Solutions companies in general or where no useful purpose is
served by identifying any particular Aker Solutions company.
February 2011
Slide 36
2011 Aker Solutions
part of Aker

Risk Based Inspection: Dynamic Optimisation of Inspection Plans

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Risk Based Inspection

Dynamic optimisation of inspection plans

2011 Aker Solutions

2011 Aker Solutions

Who we are and

2011 Aker Solutions

Aker Solutions in brief

Contract staff: 4 600

Revenues and profits are for 2010

2011 Aker Solutions

Our vision and values

All our major

2011 Aker Solutions

Aker Solutions main offerings

Mooring and loading

2011 Aker Solutions

Aker Solutions Asset Integrity Management (AIM)

Advanced Inspection &

In-Service Inspection &

Fabrication & Weld

Asset Integrity Management Services

2011 Aker Solutions

2011 Aker Solutions

2011 Aker Solutions

2011 Aker Solutions