Content

• Training Objective• Project & Activities• Project Involvement• Conclusion & Acknowledgement• Q&A Session

Training Objective

• Integrate theories with practical• Work side by side with industrial

practitioners• Introduction to work cultures and

industrial practices.• Expose student to potential employees• Develop skills in communication, work

ethics, management, etc.

• Oil & Gas Management (M) Sdn Bhd• Incorporated in 2000• Objective:

– Operation in Oil & Gas industry– Assist managing for improvement of operation through

asset integrity• Services:

Host Company Profile

PRODUCT AND SERVICES

Integrated Specialist Solution Services

Advanced NDT Inspection Services

Scoop Sampling

•Risk Based Inspection (RBI)

•Asset Integrity Management Services (AIM)

•Plant Reliability Based Mechanical Integrity

•Operation Reference Planning (ORP)

•Impact testing

•Creep testing

•Tensile Testing

•Automatic Ultrasonic Testing (AUT)

•Acoustic Emission (AE)

•Online inspection in facilities

Project & Activities

• Petronas Risk Based Inspection (PRBI)• Sabah Operation (Samarang) & Serawak Operation

(Bintulu)• Offshore Platforms:

• Bayan• Temana• D35• D18• Samarang

Project Involvement

SBOSKOPMOOffshore Platforms:

•Bayan

•Temana

•D35

•D18

Offshore Platform:

•Semarang

Project: Manage Inspection on LP Separator Vessel, V-507

P-RBI

Petronas Risk Based Inspection (P-RBI)• Systematic process to evaluate risk to turn it into

decisions concerning inspection planning.• Method designed to meet requirements of API

580.

Objectives To focus inspection resources on critical

equipment which will prevent failures.

P-RBI Benefits• Reduce costs• Provide well defined steps to improve plant

performance• Optimize inspection, test and maintenance work.• Reduce and ultimately eliminate unplanned

equipment failures.

How PRBI reduce Risk• Finding and fixing problem before lead to leaks.• An item will be removed from its service if it risk

reach unacceptable level.

P-RBI Implementation StepsIdentify Equipment

Data Collection

Equipment History

Corrosion Study/Screening Inspection

Design Data

Process Study

Field Verification/Visual Inspection

Criticality Analysis

Inspection Planning

Inspection Activities

Evaluate Results

Update Criticality

Report Results

Update Inspection Plans

Non Comformance

Identifying Equipment

Vessel Details:• Vessel Number: V-507• Vessel Description: LP Separator• Shell material: SA 516 Gr 70• Size (sq.mm) : 3076x10668

• Design Pressure: 257.296 psi• Design Temperature: 99 C• Internal Diameter: 3048 mm

Data Example

Data Collection

General Arrangement (G.A)

Ultrasound Thickness Test (U.T)

PFD and P&ID

Manufacturer Equipment Data Sheet (U-1 Report)

Data CollectionPitfalls

• Incomplete Data Collection

• Inappropriate Source

• Cut & Paste Errors

• Incorrect “units of measurement”

Data Collection

Equipment History

Corrosion Study/Screening Inspection

Design Data

Process Study

Field Verification/Visual Inspection

Inspection History : Equipment History + Visual Inspection.

Probability of leak is based on how well we know the true condition of the item.• Help to establish level of deterioration.• Rate of deterioration.• Confidence Level.

Data Collection

Equipment History

Corrosion Study/Screening Inspection

Design Data

Process Study

Field Verification/Visual Inspection

Corrosion Study:• Help to understand how equipment will fail.• Used to establish appropriate Inspection Plans.

Thickness of last inspection

Thickness of previous inspection-

Time interval in Years

Criticality Analysis

RISK

Probability•Internal Corrosion•External Corrosion•Cracking•Other Damage Mechanism

Consequences•Cost•Environmental

V-507 Shell

Probability1-Very High2-High3-Moderate4-Low5-Very Low

Probability1-Very High2-High3-Moderate4-Low5-Very Low

ConsequenceA-CatastrophicB-Very SeriousC-SeriousD-SignificantE-Minor

ConsequenceA-CatastrophicB-Very SeriousC-SeriousD-SignificantE-Minor

Inspection Priority

Category Frequency(per year)

1 > 0.1

2 0.1 - 0.01

3 0.01 - 0.001

4 0.001 - 0.0001

5 <0. 0001

Category Safety Loss (sq ft affected)

Financial Loss

A >5,000,000(450,000 sq m)

>$10 MM

B 500,000 – 5,000,000(45,000 –

450,000 sq m)

$1MM-$10MM

C 50,000 – 500,000

(4,500 – 45,000 sq m)

$100K - $1MM

D 5,000 – 50,000(450 – 4,500 sq

m)

$10K - $100K

E < 5,000(< 450 sq m)

< $10K

Probability Category

Consequences Category

Step to Calculate Criticality

Determine Internal Corrosion

Determine External Corrosion

Determine Environmental Cracking

Determine Consequences

Determine Production Loss

Summary of Criticality Ranking

Internal Corrosion

Wall ratio:

Est. min thickness

Est. wall remaining

External Corrosion

Environmental Cracking

Example of Environmental

Cracking•Wet H2S

•Amine Cracking•Carbonate Cracking

•Hydrofluoric Acid

Consequences

Production Loss

Production Loss CalculationsTotal loss= (total downtime x platform production)

x product costTotal downtime= shutdown time + reinventory time

(in hours)

Criticality

Inspection Planning

Recommended Tasks

Recommended Locations

Define Task & Locations

Inspection Management

Type of Inspection:•Visual Inspection•Ultrasonic Thickness Testing•Radiography•Penetrant Testing

Non Comformance

•Conditions found during inspection that do not meet acceptance criteria

•Non-conformance report (NCR) can be generated and tracked in P-RBI

Conclusion

•Skill enhanced•Built more confidence•Gained professional experience•Knowledge application

Acknowledgement

•Mr. Eric Ang•Mr. Quek Meng Kau•Engineers and Technicians•Dr. Ku Zilati

Q&A