HAFIZ MUHAMMAD ATIF

Module: Problem Solving

Course: MSc Asset Integrity Management

Robert Gordon University, UK

PSVM FPSO

Flixborough 1974

Grangemouth 1987

Piper Alpha 1988

Deep-water Horizon 2006

Incompetency Inappropriate Design No Identification of Barriers Absence of Process and Safety Management Absence of Integrity Management Strategy Absence of MOC process Operation outside the limits Absence of Reporting, Communication and Information Management

Asset Management Systematic and Synchronized activities through which organizations manage their assets optimal and sustainable over their life cycle to accomplish organizations strategic plans

Asset Integrity Management To manage the integrity over the life cycle of an asset.

Asset Integrity Ability of an asset to perform its function effectively and efficiently though protection the health, safety and environment.

PRINCIPLES AND ATTRIBUTES OF ASSET MANAGEMENT

Attributes Description

HOLISTIC Emphasizing the functional relation among all departments of organization

SYSTEMATIC characterized the asset management in an organized, consistent and planned manner

SYSTEMIC Affecting the whole system rather than optimizing individual asset separately

RISK – BASED:

Prioritize the assets with respect to risk (health and safety, environment and cost)

SUSTAINABLE Capable of being maintained over the life cycle without Loss of containment

OPTIMAL Best value of asset under limits of performance, cost and risk with relative to other assets

INTEGRATED Interlinking of above attributes to achieve successful Asset Management

KEY ELEMENTS OF ASSET INTEGRITY MANAGEMENT

Integrity Management System as per DNV RP 116

Concept Selection /

Design Decommissioning Operation

Hook – up Installation/

Commissioning

Procurement / Manufacturing / Construction

Integrity Management is a function of Entire Life Cycle

Maintain Integrity Design Integrity

Technical Integrity

PHASES AND STAGES OF ASSET INTEGRITY MANAGEMENT

There are three phases of integrity management 1. Design Integrity 2. Technical Integrity 3. Maintain Integrity

1. Design 2. Procurement/Construction/Manufacturing /

Installation / Hook – up 3. Commissioning 4. Operation 5. Modification 6. Decommissioning

There are six stages of integrity management

Modification

DESIGN INTEGRITY

ESTABBLISHMENT OF PILLARS TO AVOID MAJOR ACCIDENT HAZARDS

Poor material selection, Inadequate Competency, Absence of Safety Studies are the key factors for Major Accident Hazards and cause threat to Health, Safety and Environment. These can be avoid to invest money in the design stage to established an Asset Management System which ensures the facility will be capable to handle any major accident hazard which will not only protect the health and safety of the personnel's but also control environment and business risk over the life cycle of an asset. Key documentation are necessary to established the integrity are:.

Material Selection (ISO 15156; NORSOK D-001; EEMUA 194, Group Practices etc.)

Corrosion Prediction for their asset life (Multicorp, ECE, Casandra etc.)

Risk Management (Risk Assessment, Risk Management, Risk Acceptance and Risk Communication)

Conducting HAZOP, PHA, PSM, LOPA, SIMOPS Developing Safety Case (To make sure facility is enough capacity to handle

Major Accident Hazard)

Identification of SCEs (Safety Critical Elements), BCEs (Business Critical

Elements) and ICE (Integrity Critical Elements)

Integrity Management Strategy (Topside, Controls & Umbilical, Subsea Equipment, Pipelines, Riser, Corrosion, Flow Assurance, follow up with Integrity Management Plan)

Robust MOC process

TECHNICAL INTEGRITY

Manufacturing of Pressure and Non-Pressure equipment as per code and standards Construction of the facilities as per Code and Standards Robust QA / QC during Construction, Hook-up / Installation Third party inspection and verification Documentation of Anomaly Register and communicated to Operation Ensure performance standards to make sure it conforms the design intent Robust MOC process

ESTABBLISHMENT OF PILLARS TO AVOID MAJOR ACCIDENT HAZARDS

Incompetency, poor methods of manufacturing and installations, lack of communication for anomalies among the engineering departments and avoidance of third party verification are the high probable factors for damages at the infant stage of operational asset life which leads to Major Accident Hazards which can be controlled by:

OPERATIONAL INTEGRITY

Implementation of Integrity Management Strategy (Implementation of RBI, RCM, IPF and

Corrosion Management to manage the integrity and reliability of assets)

Adherence to Integrity Operating Windows Audit and Review process Continual Improvements and Lesson Learnt Enhancement of Personnel competency and skills Robust MOC process

MAINTANED PILLARS TO AVOID MAJOR ACCIDENT HAZARDS

Incompetency, Absence of integrity management strategy, lack of communication among departments , Absence of SMS (Safety Management System) and Non-conformance of operational procedures are the major causes which leads to Major Accident Hazards which can be prevent during operational life stage by:

PLAN

DO

CHECK

ACT

CONCLUSION

Organization can prevent the Piper Alpha and Deep-water Horizon GoM by establishing and maintaining the integrity over life cycle of an asset with Organization Commitment, Organizational Strategic Plans and Robust Asset Management System.

PAS 55 – 1: 2008, Asset Management, Specification for the optimized management of physical assets

PAS 55 – 2: 2008, Asset Management, Guidelines for the application of PAS 55 - 1 DNV RP F – 116, Integrity Management of Submarine Pipeline System Asset Integrity Toolkit, UKOOA OGP Asset Integrity – the key to managing major accident risks Overview of Asset Integrity Management, Robert Gordon University Document Presentation by John Reynolds, Establishing IOWs, Shell Global Solutions, IPEIA

Conference February 2, 2006, Banff, Alberta Presentation by Racehl Horne, BP, Integrity Management, Project Awareness and

Basic Application, Angola Development Program Slide Images:

1. http://www.bbc.co.uk/news/uk-scotland-22840445 2. http://www.growthaccelerator.com/wp-content/uploads/2013/03/Winning.jpg 3. http://www.chanhassenfitnessrevolution.com/wp-content/uploads/2012/07/6-Steps-to-

Success-Chanhassen-Fitness-Revolution.jpg 4. http://www.alstern-technologies.com/main_images/PLANT_2.jpg 5. http://www.seaphantom.com/images2/Offshore_platform_in_night.jpg 6. http://www.offshore-technology.com/projects/8133/images/199971/large/1l-image.jpg 7. http://static.guim.co.uk/sys-

images/Business/Pix/pictures/2010/10/19/1287476298203/Deepwater-Horizon-006.jpg 8. http://www.genesisoilandgas.com/Pages/default.aspx

REFERENCES