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Integrity Management Software SolutionManaging your daily activities.

S. Ruik BeyhautProduct Management ROSEN Integrity Solutions GmbHLingen, Germany

Contents

• Why does the industry need Asset Integrity Management?

• Why should we maintain ‘our’ tanks?

• Maintenance Excellence

• Develop Inspection Methodology

• Case Study

• ROSEN’s 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•UK 1988

•Mexico 1984

•USA 1989

•Texas City USA 2005

•Alaska Pipeline USA 2006

Tank Storage Istanbul

3 & 4 November 2010, GCH Convention Centre

Why should we maintain ‘our’ tanks ?

• Reliability (no major HSE incident)

• Availability

• Cost effective (where should we spent the money)

• Structured working process (auditable)

• Don’t create backlog

To ensure that physical assets continue to do what their users want them to do (to fulfill their intended functions)(to fulfill their intended functions)

• 1. Catastrophic failures (reputation, clean-up)$ 3 –10 M

• 2. Unplanned shutdowns (non-availability) $ 0.5 – 3 M

• 3. Planned shutdowns (cleaning, repair)$ 0.1 – 0.5 M

• 4. In-service maintenance & inspection (NDT)$ 0.01 – 0.1 M

Avoid (1)(2)

Optimize (3)

Minimize (4)

Cost associated with operating Tanks

Four stages to Maintenance Excellence

< 30% mhrs spent on PM

< 80% schedule compliance

Failure modes unknown

30 - 50% mhrs spent on PM

80%-90% schedule compliance

50-70% mhrs spent on PM

90-95% schedule compliance

> 80% mhrs spent on PM

> 95% schedule compliance

StageStage IIFireFire--fighterfighter

StageStage IIIIIIInnovatorInnovator

StageStage IVIV

MEME

StageStage IIIIControllerController

Failure modes unknown

Minimum Risk focus

Absence of PM eqpt audits

Absence of equipment criticality classification

Failure modes inventory

PM’s viewed as filler work

Major pieces of equipment classified and receive PM focus

No performance measurement

Condition based maintenance techniques

Formal PM audits and updates

Application of RBI/RCM techniques

Operators & craftsmen jointly responsible for PM

Focus on failure prevention

PM based on failure mode and failure effects

Disciplined planning & scheduling

Formal KPIs Performance analysis & improvement

• 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

CO

ST

FireFire--fightingfighting

modemode

ComfortComfort

modemode

PREVENTIVE PREVENTIVE

MTCE. COSTSMTCE. COSTS

MAINTENANCE EFFORT

NOT ENOUGH EFFORTNOT ENOUGH EFFORTNOT ENOUGH EFFORTNOT ENOUGH EFFORT OPTIMUMOPTIMUMOPTIMUMOPTIMUM TOO MUCH EFFORTTOO MUCH EFFORTTOO MUCH EFFORTTOO MUCH EFFORT

modemode modemode



COST OF NONCOST OF NON--

AVAILABILITYAVAILABILITYPROD. LOSS + BREAKDOWNPROD. LOSS + BREAKDOWN

Develop Inspection Methodology

The inspection methodology or scope should be specific for each tank:

• Design

• Product

• Potential failure mechanisms

Integrity Services:Integrity Services:

1. Inspection Services

2. Engineering Services

3. Consultancy Services

4. Integrity Management Support Services



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)Tank Storage Istanbul


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.Tank Storage Istanbul


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• 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



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

Operations

Policy

Audit & Review



Policy RequirementsPerformance

Standards Policy Review

Design/Construction Data

Asset

Data &

Design / Construction

Data

HCA Identification

Rehabilitation

Risk Re-Assessment

Integration of Pipeline, facilities

physical properties.

Data & Integrity

Management

Data Gathering

Risk-based Prioritization

Inspection Data

Integration

Immediate & Future Repair Prioritization

Rehabilitation Action

Tracking



Data Gathering

Asset

Data &


Data

HCA Identification

Rehabilitation

Risk Re-Assessment

Systematic methodology & storage to support IM process

•Data Collection & Integration

•Data Alignment > 6800km of pipelines

•Data Analysis > 260 Tanks

Data & Integrity

Management

Data Gathering


Inspection Data

Integration



Tracking

> 8000 documentsTank Storage Istanbul



Asset

Data &


Data

HCA Identification

Rehabilitation

Risk Re-Assessment

Identification & prioritization of risks to determine, how, where and when to allocate mitigation resources

•Tank Inspection prioritization

Data & Integrity

Management

Data Gathering


Inspection Data

Integration



Tracking



• 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.

Risk-based Prioritization (ROSEN’s Tank RBI methodology )

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.



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)

• RBI is a dynamic tool Tank Storage Istanbul


Risk-based Achievements (Tanks)

• Optimize routine operation on basis of condition

• Reduce out-of-service time (non-availability cost)

• Spread maintenance and inspection effort



•Budget planning and track the status

of field activities

Rehabilitation Action Tracking

Asset

Data &


Data

HCA Identification

Rehabilitation

Risk Re-Assessment

Follow up of repair actions including resource planning and NDT comparison, GIS update activities

•Coordinate tasks on the basis of both

risk and maintenance based tasks

Data & Integrity

Management

Data Gathering


Inspection Data

Integration



Tracking



Turn Key Management Solution:

Conclusion

Development Phase SupportAcceptance Phase



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.



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