surface operations integrity management - petroleum club · upstream integrated refining ... asset...

Surface Operations Integrity Management

Bucharest

March 13th 2012

2 Integrated Asset Integrity Management

OMV Petrom Group, the largest oil and gas producer in SEE

Exploration and Production

Romania and Kazakhstan Refining and

Marketing Gas and

Power

►67.77 mn boe total hydrocarbon production

►5.32 bcm Group gas production

►812 mn boe Group proved reserves

►Upstream integrated refining capacity

►~800 filling stations at Petrom Group level

►4.07 mn t Petrom Group marketing sales

►5.05 bcm Group gas sales ►Strong position on the Romanian

gas market, covering all gas market segments

►860 MW Brazi power plant to start commercial operations in H2/2012

All figures as of December 2011; figures refer to Petrom Group


Exploration and Production Facts and figures

Romania ► Proved reserves at end of 2011 in Romania: 786 mn

boe ► Reserves replacement rate in 2011: 70% ► Crude oil and NGL production in 2011: 33.08 mn bbl

Kazakhstan ► Proved reserves at end of 2011: 26 mn boe ► Crude oil and gas production: 4.36 mn boe


Definition of ASSET INTEGRITY from OGP

► Asset integrity is related to the prevention of major incidents. It is an outcome of good design, construction and operating practices. It is achieved when facilities are structurally and mechanically sound and perform the processes and produce the products for which they were designed.

► The emphasis is on preventing unplanned hydrocarbon releases that may, either directly or via escalation, results in a major incident.


Emphasis on Process Safety • Process Safety is a disciplined

framework for managing the integrity of hazardous operating systems and processes by applying good design principles, engineering and operating practices.

• It deals with the prevention and control of incidents that have the potential to release hazardous materials or energy.

• Such incidents can cause toxic effects, fire or explosion and could ultimately result in loss of life, serious injuries, property damage, environmental impact and lost production


Relationship Asset Integrity & Process Safety

Owned & Assured by HSSE

PSM System AIM


Integrity Program

Integrity Program to bring facilities up to compliance with regulatory requirements in terms of ► Legal requirements ► Environmental requirements ► Technical condition ► Safety

► Prioritization done based on risk assessment and existing condition assessments


Integrity Program


Integrity Management Program

MIRD Program-Fix Derricks

Gas conditioning

Inlet Manifolds, Piping's, Valves Tanks / Habas

Process Safety (PSV’s, Pipework and Venting)

Wellhead X-mas Trees - New Electrical network – power system

ESD&Fire&Gas Detection Pipelines

Boilers & Heaters

H2S and CO2 (detection, escape eqpt. & training of operators)

Replace Boldesti De Gasolinization facility with LTS

Integrity Management Program includes 14 work streams

Technical Documentation Roads Integrity


Surface Facilities and Pipelines Information and Processes Organization

Asset Integrity

► Risk Based Approach to 2012 High risk facilities (14 work streams, 25 M Euro)

- Mgt of high risk facilities against Earthquake and Flood

- Critical Infrastructure program ► RBI (Static Equipment) and PIMS - Pilot Study Asset 2 High Risk Gas asset - Roll out to all Assets 2012 - Pipeline Prioritization Project for repair and

replacement - Risk Rank High Risk Facilities ► Engineering and Design - Process Safety standard incorporated in design

phase ► Inspection and Maintenance - Maintenance Strategy Review ► Corrosion management - Corrosion Inhibition Program 5000+ wells ► Facility Abandonment - Pipeline Abandonment Program new PI

department

► Technical Documentation - Document Mapping: Identify & develop all

Operational Doc. in HQ, Assets and Projects ► MOC - Eng Change Proced. developed and process in

function ► Permit To Work - Pilot e Permit System Asset X ► Operational Readiness Assurance - Dedicated resource to all new projects ► Process Safety - Safety Critical Elements identified - Perform Stand Brown & Greenfield sites - SAP align, custom FL and WO screens - PS MWA & KPI’s ► IT System & Data Management - ePermit - SCE Database - RBI and PIMS Software - SAP Data Integrity gap analysis ► Audit - PS and SCE Audit

► Organization - Dedicated PIM Team set up in HQ - Pipeline & Static Equipment RBI teams in

Assets - Dedicated PS Resource per asset ► Accountabilities - New JD’s and R&R for new teams in HQ and

Assets - Redefine Operator R&R and first line

maintenance ► Training and Competency - JD redefined for new organization - Training and Competency Matrix to be

developed - Gap Analysis and program establish - RBI Training (Methodology and Software) - Bowtie Risk assessment training complete

Asset Integrity Management Pillars


Safety Critical Elements

►Safety Critical Element (SCE) - Any part of the facilities (including software) the failure of which could cause or contribute substantially to a major accident, or the purpose of which is to prevent or limit the effects of a major accident.

►Guideline for Identifying Safety Critical Elements - EP-HQ-03-GL-008-OO


Process Safety Management Plan – Greenfield (Hurezani & Midia)

Risk Assessment

Barriers

Performance Standards

Verify Performance

Act

on

outc

omes

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Safety Case Major Accident Hazard focused risk assessment report – identifies MAH

Hazard Register describes barriers and SCE are defined.

Issues register is generated

Performance Standards developed and Safety Critical Equipment are identified in maintenance system.

Written Scheme of Verification created and Inspections & maintenance conducted

Safety critical elements are normally identified as a result of a safety case and hazard register development during the design stage


BOW Tie: Hydrocarbon Containment


Process Safety Management Plan – Brownfield

OMV SCE Guidelines

Generic Barriers & Analysis

Generic Performance Standards

Verify Performance

Act

on

outc

omes

and

upd

ate

OMV SCE Guideline EP-HQ-03-GL-008-00 for Facilities where no HSE Case exists

SCE are defined using flowchart for identifying safety critical elements

Issues register is generated

Generic Performance Standards developed and Safety Critical Equipment are identified in maintenance system.

Written Scheme of Verification created and Inspections & maintenance conducted

Where a formal risk assessment is not available to identify safety critical elements an alternative approach is required


Flowchart for Identifying Brownfield SCEs

Guideline for Identifying Safety Critical Elements EP-HQ-03-GL-008-00


SAP record for Functional Location


Start up and Year 1 management is crucial for a successful program lifecycle

►SOI department in 2012 is responsible for management, control and execution of a high number of integrity projects with significant impact on Petrom E&P, Operations, HSSE and process safety.

► Different scopes of work with need for alignment & interdependency management between subprojects & work streams

► Need for interaction and coordination with other departments ► High visibility and delivery to Senior Management (significant budget allocation )

►Need for audit proof management processes (incl. documentation) ►Expansion of SOI department scope and project landscape − Pipeline Integrity Team − Petrom Risk Management (Floods & Earthquakes) − Critical infrastructure − Inclusion of all Pipeline and Roads Projects 2013 ►Significant risks to be considered and mitigated ►Review and propose Integrity Program for 2013 (budgets, risk workshops, action plan)

Current situation / challenges

Thank You

surface operations integrity management - petroleum club · upstream integrated refining ... asset...

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