ASSET INTEGRITYASSET INTEGRITYMANAGEMENTEnsuring the Integrity, Safety and Reliability of Plant

OBJECTIVES OF ASSET OWNERSOBJECTIVES OF ASSET OWNERS

Regulatory Compliance

Maximise production

Reduce lost income due to unplanned shutdowns

Optimise inspection & maintenance p pcosts

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ASSET INTEGRITY MANAGEMENTASSET INTEGRITY MANAGEMENT

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

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MANAGEMENT COMMITMENTMANAGEMENT COMMITMENT FROM DESIGN THROUGH TO OPERATION

ProcurementDesign

ConstructionOperation

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SGS AIM SUMMIT- NOV 2013

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SGS AIM SUMMIT-A PLATFORM TO DISCUSS INDUSTRIAL ASSETS PROBLEMS

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ASSET LIFE CYCLEASSET LIFE CYCLE

D i R i f Vendors AuditDesign Review for

Engineering & Safety

Vendors Audit

QA of Equipment

d i f tProcurment

Design

Codes during manufacture

Engineering/Construction

Operation Documented QA PlanRisk Assessment Construction Documented QA Plan,

Inspection/testing and

Dossier of records

Risk Assessment,

Monitoring &

Mi i i Dossier of recordsMitigation

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HISTORYHISTORY

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RISK BASED INSPECTION

A systematic approach to identify the potential degradation h i d h h i i f h i dmechanisms and threats to the integrity of the equipment and to

assess the consequences and risks of failure

Risk = Probability x Consequence

High

Medium-High

MediumRisk Ranking

Low

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RBI WORK FLOW

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OUTCOME OF RBIRisk Matrix of Equipment

Inspection strategyWHAT – The equipment that needs to be inspected

WHERE – The location of Inspection

WHEN – The optimum interval between inspectionWHEN The optimum interval between inspection

HOW – Specify the right technique to detect the defects that aparticular component is most likely to develop.

HOW MUCH – The coverage (extent) of inspection.

Operating Window

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Operating Window

ADVANCED & NON-INTRUSIVE INSPECTION TECHNIQUESINSPECTION TECHNIQUES

Time of Flight Diffraction [TOFD]Phased Array weld InspectionPhased Array weld InspectionGuided Wave Long Range Ultrasonic, LRUTMagnetic Flux Leakage testing of tank bottom[MFL]Magnetic Flux Leakage testing of tank bottom[MFL]ThermographyTubing Inspection, EC, IRIS, RFT, MFLTubing Inspection, EC, IRIS, RFT, MFLVideoscopy with sizing capabilityAutomated UT weld scanning & Corrosion Mapping g pp gCHIME, rapid non invasive Scanning of pressure vessels Automated UT Crawler for tank shell UT monitoringFlange Face Phased Array scanningField Metallography

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PMI (Positive Material identification)

ADVANCED & NON-INTRUSIVE INSPECTION TECHNIQUESTECHNIQUES

Guided Wave Long Range UltrasonicPipeline Screening for corrosion spotsPipeline Screening for corrosion spots

Phased Array weld Inspectiony pWeld inspection -New-construction & in-service

Time of Flight Diffraction [TOFD]Weld inspection

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ThermographyHeat losses

Tubing Inspection, EC, IRIS, RFT, MFLHeat-Exchanger

Videoscopy with sizing capabilityEngines, turbines, pipes, nozzles, vessels, etc.CHIMEInaccessible areasInaccessible areasclamps and saddlespipe supports tank floorspipe supports, tank floorshalf buried pipes.

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Flange Face Phased Array scanningboth flange seal face surfaces simultaneouslyboth flange seal face surfaces simultaneously

Field Metallographymicro structural changes in a component.

Magnetic Flux Leakage (MFL) testingt k b tt d id i it itank bottoms under side corrosion monitoring.

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DATA MANAGEMENTProject PerformanceIndicatorsShutdown & Maintenance

D t ti

Corrosion Monitoring Inspection

Tracking & Reporting Systems

Tags PSV’s RMS

Documentation

Monitoring Inspection Data

Mechanical & ProcessD

Tags PSV s RMS, Rotating & Static,PipelinesLifting EQ .HSE??Data

EquipmentDocumentation

Lifting EQ .HSE

Corrosion Monitoring,Next inspection,

Remaining Life? ?

Regulatory Documentation

Documentation Remaining Life

Inspection and MaintenanceInspection and MaintenancePlanningPlanning

Local & Global ReportingCAD & Inspection IsometricsDrawings

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ONE WINDOW SOLUTION Risk BasedInspection Recommendations

Technical / DesignDatasheets

Condition Alerts

Operating Envelopes/ CP Alert

Thickness MonitoringInspection Management / CP Alert

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SGS CAN ASSIST

Risk Based Inspection Services

Inspection Program ExecutionCertified Engineers & Inspectors -API, NDT, ASME, NACEPool of conventional & advanced NDT techniquesPool of conventional & advanced NDT techniquesData evaluation, recommendation and FFS assessment.

Inspection Data ManagementInspection Data ManagementTrend Monitoring and Inspection work generation

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