ASSET INTEGRITY MANAGEMENT

Transcription

1 ASSET INTEGRITY MANAGEMENT Ensuring the Integrity, Safety and Reliability of Plant

2 OBJECTIVES OF ASSET OWNERS Regulatory Compliance Maximise production Reduce lost income due to unplanned shutdowns Optimise inspection & maintenance costs 2

3 ASSET INTEGRITY MANAGEMENT To maintain the asset in a fit-for-service condition while extending its remaining life in a the most reliable, safe and cost effective manner 3

4 MANAGEMENT COMMITMENT FROM DESIGN THROUGH TO OPERATION Design Procurement Operation Construction 4

5 SGS AIM SUMMIT- NOV

6 SGS AIM SUMMIT-A PLATFORM TO DISCUSS INDUSTRIAL ASSETS PROBLEMS 6

7 ASSET LIFE CYCLE Design Review for Vendors Audit Engineering & Safety QA of Equipment Codes Procurment Design during manufacture Operation Engineering/ Construction Risk Assessment, Construction Documented QA Plan, Monitoring & Inspection/testing and Mitigationi i Dossier of records 7

8 HISTORY 8

9 RISK BASED INSPECTION A systematic approach to identify the potential degradation mechanisms and threats to the integrity i of the equipment and to assess the consequences and risks of failure Risk = Probability x Consequence High Medium-High Medium Risk Ranking Low 9

10 RBI WORK FLOW 10

11 OUTCOME OF RBI Risk Matrix of Equipment Inspection strategy WHAT The equipment that needs to be inspected WHERE The location of Inspection WHEN The optimum interval between inspection HOW Specify the right technique to detect the defects that a particular component is most likely to develop. HOW MUCH The coverage (extent) of inspection. Operating Window 11

12 ADVANCED & NON-INTRUSIVE INSPECTION TECHNIQUES Time of Flight Diffraction [TOFD] Phased Array weld Inspection Guided Wave Long Range Ultrasonic, LRUT Magnetic Flux Leakage testing of tank bottom[mfl] Thermography Tubing Inspection, EC, IRIS, RFT, MFL Videoscopy with sizing capability Automated UT weld scanning & Corrosion Mapping CHIME, rapid non invasive Scanning of pressure vessels Automated UT Crawler for tank shell UT monitoring Flange Face Phased Array scanning Field Metallography PMI (Positive Material identification) 12

13 ADVANCED & NON-INTRUSIVE INSPECTION TECHNIQUES Guided Wave Long Range Ultrasonic Pipeline Screening for corrosion spots Phased Array weld Inspection Weld inspection -New-construction & in-service Time of Flight Diffraction [TOFD] Weld inspection 13

14 Thermography Heat losses Tubing Inspection, EC, IRIS, RFT, MFL Heat-Exchanger Videoscopy with sizing capability Engines, turbines, pipes, nozzles, vessels, etc. CHIME Inaccessible areas clamps and saddles pipe supports, tank floors half buried pipes. 14

15 Flange Face Phased Array scanning both flange seal face surfaces simultaneously Field Metallography micro structural changes in a component. Magnetic Flux Leakage (MFL) testing tank bottoms under side corrosion monitoring. i 15

16 Shutdown & Maintenance Documentation ti Corrosion Monitoring Inspection Data Mechanical & Process Data Equipment Documentation Regulatory Documentation CAD & Inspection Isometrics Drawings DATA MANAGEMENT Project Performance Indicators? Tracking & Reporting Systems Tags PSV s RMS, Rotating & Static,Pipelines Lifting EQ.HSE Corrosion Monitoring, Next inspection, Remaining Life Inspection and Maintenance Planning Local & Global Reporting 16

17 ONE WINDOW SOLUTION Risk Based Inspection Recommendations Technical / Design Datasheets Condition Alerts Inspection Management Operating Envelopes / CP Alert Thickness Monitoring 17

18 SGS CAN ASSIST Risk Based Inspection Services Inspection Program Execution Certified Engineers & Inspectors -API, NDT, ASME, NACE Pool of conventional & advanced NDT techniques Data evaluation, recommendation and FFS assessment. Inspection Data Management Trend Monitoring and Inspection work generation 18