1 - Overflate 2015 / Frode A. Kvilhaug
Statoil insulation requirements and the effect on total project cost Frode A. Kvilhaug Leading Advisor Surface Protection and Polymer Materials Statoil
Agenda:
• Statoil experience on what factors driving up the cost in projects?
• What can be done to challenge this cost increasing factors?
• Qualification and competence activities internally in Statoil
• TR1660 - Piping and equipment insulation – What is new?
• Expected results from the activities and new technical requirements?
2 Overflate 2015 / Frode A. Kvilhaug
Statoil experience on what factors driving up the cost in projects
• Insulation is handled late in the project – During construction phase
− Not optimal design
− No time for critical evaluation of where and how much to insulate
− Activities controlled by the insulation contractor
• Lack of insulation competence in the project
− All activities and planning run by the insulation contractor
− Insulation based on supplier not general solution
− No critical review of the insulation work
• Lack of implementing all relevant disciplines in the insulation scope
3 Overflate 2015 / Frode A. Kvilhaug
Insulation SOW
Process
Technical safety
Work environment
Knock on effect on: • Supports • Space • Coating • Weight • Engineering and construction • Follow up • Operations - CUI
Instrument
Architect
“More effort on challenging the insulation scope, investigating and implementing smarter technical solutions could also have had significant impact.” – project experience report
Insulation
HVAC
Overflate 2015 / Frode A. Kvilhaug 4
Lack of knowledge about the technical requirements?
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Requirements and best practice related to insulation and CUI management in Statoil
6
Insulation
TR1660 Piping and equipment insulation
NORSOK R-004 Piping and equipment insulation
Weather protection
TR1660 Piping and equipment insulation
Other requirements
TR3102 Materials Selection for Development and Modification Projects
TR3016 Piping repair and cold installation methods
Safety/acoustic requirements
Inspection and maintenance TR1660 Piping and equipment insulation
TR0007 Requirements for coating Maintenance
TR1987 Program activity requirements for static process equipment and load-bearing structures
GL0560 Prioritering av vedlikehold for statisk prosessutstyr utsatt for korrosjon under isolasjon
TR2391 Preventive activities requirements for Rigid Pipeline Systems
TR2392 Program Activity Requirements for Flexible Pipelines
Coating
TR0042 Surface preparation and protective coating
TR0007 Requirements for coating Maintenance
Norsok M-501 Surface preparation and protective coating
Overflate 2015 / Frode A. Kvilhaug
What can be done to challenge this cost increasing factors?
• Introduce the insulation scopes earlier in the project
• Higher focus in the projects on the insulation discipline
• Increase competence in the company/projects
− Workshops
− Multi discipline collaboration meetings
− Meetings with suppliers/contractors
− Core group meetings
• Challenge the “known facts”
− Study documentation from suppliers, papers etc.
− Internal testing
• Implement the achieved knowledge into Technical Requirements.
7 Overflate 2015 / Frode A. Kvilhaug
Qualification and competence activities internally in Statoil
• Corrosion under insulation project and workshops
• Supplier meetings
• Passive fire protection multidiscipline internal project
• Workshops insulation and PFP
• Bi-monthly core group meetings
• Communication through internal network
• Communication of the requirements internally
• Testing in Porsgrunn
8 Overflate 2015 / Frode A. Kvilhaug
TR1660 - Piping and equipment insulation
What is new?
9 Overflate 2015 / Frode A. Kvilhaug
More prescriptive requirements
• Type of qualified insulation material
• Type of sealer and gasket material – App C
10 Overflate 2015 / Frode A. Kvilhaug
More prescriptive requirements
• New solutions are subject to a written approval by Company
− Company in charge of what being approved.
• New solutions for use of bolt protection for passive fire protection given in Insulation Handbook
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TR1660 - What else is new?
• Insulation Handbook now a part of the document – Easier access for contractors
12 Overflate 2015 / Frode A. Kvilhaug
Early focus on insulation in projects
• An insulation philosophy shall be established in the FEED phase.
• An insulation strategy and material selection report shall be established and form the basis for the detailed engineering and selection of insulation materials
• A construction strategy for insulation shall be developed
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Early focus on insulation in operations
• A construction strategy for insulation shall be developed
• Selection of materials shall be documented in a Material Selection Report
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What is the expected results from the activities and new technical requirements?
15 Overflate 2015 / Frode A. Kvilhaug
Lower weight of facilities
• Slimmer design
• Lower weight of insulation solutions
• Less insulation
16 Overflate 2015 / Frode A. Kvilhaug
No corrosion under insulation (CUI)
• Less insulation – Less possible CUI areas
• Good workmanship – More correct solutions
• Using only approved products and solutions – Tested for best resistance towards CUI
• Better insulation competence – Better total understanding and monitoring of the insulation work.
17 Overflate 2015 / Frode A. Kvilhaug
Other expected results from the activities and new technical requirements
• High status for insulation work and thereby focus on insulation requirements
• Less time used in discussions with contractors over requirements and deviations
• Greater knowledge internally (and externally) will result in better decisions.
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Conclusion
Early focus on insulation
Correct on the requirements
Greater insulation knowledge
No CUI
Saving weight
Saving cost (Capex and Opex)
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20 Overflate 2015 / Frode A. Kvilhaug
Frode A. Kvilhaug, Statoil ASA Leading Advisor Surface Treatment and Polymers
[email protected] mob: +47 48 26 13 61
www.statoil.com
Thank you! Statoil insulation requirements and the effect on total project cost