Final Slide OGM
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Transcript of Final Slide OGM
Content
• Training Objective• Project & Activities• Project Involvement• Conclusion & Acknowledgement• Q&A Session
Training Objective
• Integrate theories with practical• Work side by side with industrial
practitioners• Introduction to work cultures and
industrial practices.• Expose student to potential employees• Develop skills in communication, work
ethics, management, etc.
• Oil & Gas Management (M) Sdn Bhd• Incorporated in 2000• Objective:
– Operation in Oil & Gas industry– Assist managing for improvement of operation through
asset integrity• Services:
Host Company Profile
PRODUCT AND SERVICES
Integrated Specialist Solution Services
Advanced NDT Inspection Services
Scoop Sampling
•Risk Based Inspection (RBI)
•Asset Integrity Management Services (AIM)
•Plant Reliability Based Mechanical Integrity
•Operation Reference Planning (ORP)
•Impact testing
•Creep testing
•Tensile Testing
•Automatic Ultrasonic Testing (AUT)
•Acoustic Emission (AE)
•Online inspection in facilities
Project & Activities
• Petronas Risk Based Inspection (PRBI)• Sabah Operation (Samarang) & Serawak Operation
(Bintulu)• Offshore Platforms:
• Bayan• Temana• D35• D18• Samarang
Project Involvement
SBOSKOPMOOffshore Platforms:
•Bayan
•Temana
•D35
•D18
Offshore Platform:
•Semarang
Project: Manage Inspection on LP Separator Vessel, V-507
P-RBI
Petronas Risk Based Inspection (P-RBI)• Systematic process to evaluate risk to turn it into
decisions concerning inspection planning.• Method designed to meet requirements of API
580.
Objectives To focus inspection resources on critical
equipment which will prevent failures.
P-RBI Benefits• Reduce costs• Provide well defined steps to improve plant
performance• Optimize inspection, test and maintenance work.• Reduce and ultimately eliminate unplanned
equipment failures.
How PRBI reduce Risk• Finding and fixing problem before lead to leaks.• An item will be removed from its service if it risk
reach unacceptable level.
P-RBI Implementation StepsIdentify Equipment
Data Collection
Equipment History
Corrosion Study/Screening Inspection
Design Data
Process Study
Field Verification/Visual Inspection
Criticality Analysis
Inspection Planning
Inspection Activities
Evaluate Results
Update Criticality
Report Results
Update Inspection Plans
Non Comformance
Identifying Equipment
Vessel Details:• Vessel Number: V-507• Vessel Description: LP Separator• Shell material: SA 516 Gr 70• Size (sq.mm) : 3076x10668
• Design Pressure: 257.296 psi• Design Temperature: 99 C• Internal Diameter: 3048 mm
Data Example
Data Collection
General Arrangement (G.A)
Ultrasound Thickness Test (U.T)
PFD and P&ID
Manufacturer Equipment Data Sheet (U-1 Report)
Data CollectionPitfalls
• Incomplete Data Collection
• Inappropriate Source
• Cut & Paste Errors
• Incorrect “units of measurement”
Data Collection
Equipment History
Corrosion Study/Screening Inspection
Design Data
Process Study
Field Verification/Visual Inspection
Inspection History : Equipment History + Visual Inspection.
Probability of leak is based on how well we know the true condition of the item.• Help to establish level of deterioration.• Rate of deterioration.• Confidence Level.
Data Collection
Equipment History
Corrosion Study/Screening Inspection
Design Data
Process Study
Field Verification/Visual Inspection
Corrosion Study:• Help to understand how equipment will fail.• Used to establish appropriate Inspection Plans.
Thickness of last inspection
Thickness of previous inspection-
Time interval in Years
Criticality Analysis
RISK
Probability•Internal Corrosion•External Corrosion•Cracking•Other Damage Mechanism
Consequences•Cost•Environmental
V-507 Shell
Probability1-Very High2-High3-Moderate4-Low5-Very Low
Probability1-Very High2-High3-Moderate4-Low5-Very Low
ConsequenceA-CatastrophicB-Very SeriousC-SeriousD-SignificantE-Minor
ConsequenceA-CatastrophicB-Very SeriousC-SeriousD-SignificantE-Minor
Inspection Priority
Category Frequency(per year)
1 > 0.1
2 0.1 - 0.01
3 0.01 - 0.001
4 0.001 - 0.0001
5 <0. 0001
Category Safety Loss (sq ft affected)
Financial Loss
A >5,000,000(450,000 sq m)
>$10 MM
B 500,000 – 5,000,000(45,000 –
450,000 sq m)
$1MM-$10MM
C 50,000 – 500,000
(4,500 – 45,000 sq m)
$100K - $1MM
D 5,000 – 50,000(450 – 4,500 sq
m)
$10K - $100K
E < 5,000(< 450 sq m)
< $10K
Probability Category
Consequences Category
Step to Calculate Criticality
Determine Internal Corrosion
Determine External Corrosion
Determine Environmental Cracking
Determine Consequences
Determine Production Loss
Summary of Criticality Ranking
Internal Corrosion
Wall ratio:
Est. min thickness
Est. wall remaining
External Corrosion
Environmental Cracking
Example of Environmental
Cracking•Wet H2S
•Amine Cracking•Carbonate Cracking
•Hydrofluoric Acid
Consequences
Production Loss
Production Loss CalculationsTotal loss= (total downtime x platform production)
x product costTotal downtime= shutdown time + reinventory time
(in hours)
Criticality
Inspection Planning
Recommended Tasks
Recommended Locations
Define Task & Locations
Inspection Management
Type of Inspection:•Visual Inspection•Ultrasonic Thickness Testing•Radiography•Penetrant Testing
Non Comformance
•Conditions found during inspection that do not meet acceptance criteria
•Non-conformance report (NCR) can be generated and tracked in P-RBI
Conclusion
•Skill enhanced•Built more confidence•Gained professional experience•Knowledge application
Acknowledgement
•Mr. Eric Ang•Mr. Quek Meng Kau•Engineers and Technicians•Dr. Ku Zilati
Q&A