Ray Goodfellow

7/30/2019 Ray Goodfellow

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Incorporating an Asset

Integrity Program into the

Design Stageof Projects

Ray GoodfellowPangea Solutions IncMay 9, 2008

[email protected]
mailto:[email protected]:[email protected]


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What is Asset Integrity Asset Integrity is an effective system for

managing the integrity of equipment, piping andpipelines throughout the full lifecycle: design

construction & installation operation

maintenance, (repairs, alterations)

integrity assessments

decommissioning

Developing and implementing an Asset Integrityprogram at the design stage supports lifecyclereliability and operability


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What is Asset Integrity Regulatory Requirements (ABSA/CSA/EUB/)

Pressure Equipment Integrity Management System(PEIMS)

Pipeline Integrity Management Program

Key elements include:Risk assessments

Degradation Circuits

Material selection

Condition monitoring location (CML) selection Inspection, Mitigation, Monitoring

Data management

Training programs


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What is Asset Integrity

Typical Equipment within Scope: Boilers and heaters

Pressure vessels (including Pressure relief devices)

Pressure piping

Tanks Non-pressure static equipment

Non-pressure piping

Pipelines

Not in Scope Structural

Rotating equipment

Electrical


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Overview

Why:

What is the value of incorporating Asset Integrity into

the design stage of a project?

How:

What are the key activities at each stage of the

project?

Deliverables: What are the deliverables at each stage of the

project?


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Why

De-ethanizer overhead gas

line

erosion corrosion

failure downstream of mixing

point

Humber Refinery Fire, Health Safety Executive (HSE) Report

http://www.hse.gov.uk/offshore/information.htm\
http://www.hse.gov.uk/offshore/information.htm/http://www.hse.gov.uk/offshore/information.htm/http://www.hse.gov.uk/offshore/information.htm/


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Why incorporate Asset Integrity into

the design stage of a project The goal of each project is to create a business asset

that performs its intended function, is safe,environmentally sound and reliable. The project is expected to be executed within the planned cost

and schedule

* I cant emphasize enough that youve got to get this right.You got to get this right. Because when you finally lock thescope, youre stuck with it for 30, 40, 50 years, so you betternot have any regrets when you start building it and running itthat you didnt get it right

~Neil Camarta

*Petro-Canada Investor Day: Fort HillsOil Sands Engine of Growth, Neil Camarta, Senior Vice-President, OilSands


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You got to get this right

Incorporate lifecycle asset integrity into the

design

Have a positive impact:

for the project efficient project execution

and optimize capital costs

for the operation- improve reliability andoperability


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Incorporate lifecycle asset integrity into

the design Make well thought out

decisions to meet project

and operations objectives

Good decisions include:

Involving the right people

Having a structured process

to guide decision making

Maintaining good

documentation


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Incorporate lifecycle asset integrity

into the design Increased upfront engineering can:

Support quality decisions regarding CAPEX (design

mitigation) and OPEX (operational mitigation) Provide clarity and direction that reduces time in

detailed engineering

Reduce rework during fabrication and during

operationsMeet operational reliability expectations for long term

plant life


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Trend in Industry

Understanding of the importance ofincorporating Asset Integrity into the designstage is increasing due to serious failures in the

refinery, petrochemical and pipeline industryMajor corporations now require risk assessments at

the design stage.

Regulator requires the effective systems formanaging the integrity of their pressure equipmentthroughout its full lifecycle which includes design,construction and installation.


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How

Incorporate asset integrity activities into key

phases of the project

Identify key project objectives, development phases,

milestones and hold points Utilize defined processes (i.e. Risk Base Inspection)

to make decisions

Supply defined deliverables at each stage of the

projectRecognize, understand, and quantify the impacts and

values added from asset integrity activities


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Key activities and deliverables at

each stage of the project Companies have multi step project

management processes

1. Select Alternatives2. Front End Engineering

3. Detailed Engineering

4. Fabrication and Construction

5. Commissioning6. Turn Over to operations


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1. Select Alternatives

Key ProcessesDesign Basis Risk Assessment

Lessons Learned Study

Key DeliverablesAsset Integrity design philosophy report

Lessons learned report

Technical work book with all supporting

information. (dynamic document) The work book will form the basis of additional risk

assessments and the integrity manuals for theoperating facilities


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1. Select Alternatives Impact

Business basis for integritymanagement strategy

Risk based decisions thatconsider full asset lifecycle Design mitigation

Alloys, coatings, equipmentdesign, process changes

Operational mitigation Inhibition, process control,

inspection, monitoring, run to

failureAlternative selection considers

potential degradationmechanisms and otherhazards


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2. Front End Engineering Key Activities

Risk Assessment

Incorporate lessons learned

Development/Updating of Standards

Management of Change Key Deliverables

Scope and budget includes asset integrity and QAwork

Technical work book with all supporting information.

New or revised specifications

Documented basis of integrity related designdecisions


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2. Front End Engineering

Impact Scope and costs for integrity

related work are included inproject budget

Determine first plannedshutdown Equipment isolation and

inspection plan

Design mitigation

i.e. select materials and designOperational mitigation

i.e. select mitigation andmonitoring strategy


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3. Detailed Engineering Key Processes

Assessment of deviations from initial design Previous Risk Assessment methodology can be used

Materials selection report and diagram (MSD) reviews

P&ID reviews

Development/Implementation of quality assurance program

Key Deliverables

Reports or recommendations on specific technical issues Equipment Integrity Manuals

Based on technical work books

Degradation circuits

Document the basis of design decisions

Incorporates information from reports or recommendations on specific

technical issues Foundation of RBI and overall asset integrity program

Incorporate EPC Information

Condition Monitoring Location (CML) selection

Corrosion monitoring locations

QA issues


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3. Detailed Engineering Impact

Provide technical input atproject reviews, hold points,and milestones

Capture the technical basisand rational behind material,mitigation, monitoring andinspection decisions Understanding the rational

allows more effectivemanagement of future changes(personal and process)

3D Modeling can be used forselection of CMLs, corrosionmonitoring locations, etc.


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Key ActivitiesQuality assurance and Quality control

a key aspect of asset integrity

Vendor audits and reviews

Assessment of deviations from design

Key Deliverables Updated equipment integrity manuals

Baseline CML survey on critical equipment and pipingcompleted

Start populating equipment data base


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Impact

Final product

meets design

specifications

Have base line

data


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5. Commissioning Key Activities

Assessment of deviations from design

Regulatory requirements prior to start up

Plan for start up activities

Key Deliverables Installation Inspections compete

PSVs serviced

Equipment integrity manual complete

Equipment database is populated with new equipment

Baseline TML complete on critical equipment and piping

Complete training for critical tasks


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5. Commissioning Impact

All critical tasks have

been completed prior

to start up

Installation inspections

and PSV servicing Inhibition programs in

place

Monitoring programs in

place

Training on procedurescompleted


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6. Hand Over to Operations

Key Processes Training

Key Deliverables Equipment Integrity Manuals

Documentation of deviations from design

Populated database

Mitigation and monitoring planMaintenance planning

Long term training program


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6. Hand Over to Operations Impact

A business asset that is safe, environmentally sound and reliable
http://www.chemicals-technology.com/projects/safco/index.html

Ray Goodfellow

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