PLANT INTEGRITY MANAGEMENT

PRESENTED BY

VIJAY VESVIKAR

NDT Level III, CSWIP 3.1, API 570

MANAGER QA, NPC

MANAGE

INTEGRITY

RISKS OF

AGING

ASSETS

INTRODUCTION

INDUSTRY DYNAMICS &

PRESSURES

ELEMENTS OF AN INTEGRITY

MANAGEMENT STRATEGY

ORGANIZATIONAL COMPETENCE

ASSET LIFE CYCLE APPROACH TO

ASSET & INTEGRITY MANAGEMENT

CASE STUDY – PIPEWORK

CONCLUSION

HOW TO MAINTAIN

PRODUCTION CAPABILITY

IN A COST-EFFECTIVE

WAY WHILE PRESERVING

THE INTEGRITY OF

THOSE ASSETS ?

DEVELOP & IMPLEMENT

AN EFFECTIVE ASSET

INTEGRITY

MANAGEMENT

APPROACH

INDUSTRY

DYNAMICS &

PRESSURES

ECONOMIC DOWNTURN

EXTENDED LIFE BEYOND

ORIGINAL DESIGN LIFE

Initiatives to Gauge Life

Extension of an Asset :

Criticality Assessment

Risk Based Inspection ( RBI )

Reliability Centered Maintenance

( RCM )

FACTORS COMPROMISING

INTEGRITY OF AN ASSET

MODIFICATIONS

OPERATING EXCURSIONS OUTSIDE

OF OPERATING ENVELOPE

STRESSES EXCEEDING FATIGUE

DESIGN LIFE

OPERATING FOR LONGER PERIODS

THAN ASSUMED

SAFETY

INTEGRITY

RELIABILITY

RISK MANAGEMENT

DEVELOPMENT OF PROGRAM

SAFETY

HEALTH

ENVIRONMENT IMPACT

PRODUCTION LOSS

PEDIGREE OF THE ASSETS

UPGRADATION PLAN

Main Elements of an

Integrity Management

Review

1. Reliability & Integrity of the

Assets Themselves

2. Effectiveness of the Systems &

Procedures in place

3. Knowledge & Competence of the

Workforce

HUMAN FACTORS

MANAGEMENT UNDERSTANDING

AND SUPPORT

COMMUNICATION ACROSS THE

LIFECYCLE

EFFECTIVE COMMUNICATION

SYSTEM

DESIGN & CONSTRUCTION

FEATURES

DEGRADATION MECHANISM

ELEMENTS OF AN

ASSET INTEGRITY

MANAGEMENT

STRATEGY

ASSET STRATEGY MUST

DEFINE THE

REQUIREMENTS TO BE

PLACED ON THE ASSETS

TO SUPPORT BUSINESS

STRATEGY

POLICIES :

SAFETY

MAINTENANCE

INSPECTION

RENEWAL

COMPETENCE

SAFETY POLICY

HAZARDS

MEASURES

PROCESS

RESIDUAL RISKS

OPERATING LIMITS

EXCURSIONS

MAINTENANCE POLICY

SAFETY & HEALTH

ENVIRONMENT

PRODUCTION

OPTIMUM BALANCE FOR

MAINTENANCE

FITNESS FOR PURPOSE &

INTEGRITY FOR OPERATIONS

INSPECTION POLICY

TYPE OF EQUIPMENT

SPECIFIC AREA

TYPE OF INSPECTION

TECHNIQUES

FREQUENCY

DOCUMENTATION

RENEWAL POLICY

END OF LIFE ON AN EQUIPMENT

LIFE LIMITING DETERIORATION

MECHANISM

OBSOLESCENCE

LIFE EXTENSION

SIGNIFICANT REPAIR

MAINTENANCE & INSPECTION

COMPETENCE POLICY

CORE COMPETENCE

BASICS OF CORE COMPETENCY

EXTERNAL RESOURCES

STRENGTHENING MECHANISMS

ORGANIZATIONAL

COMPETENCE

COMPETENCE

COMMITMENT

COMMUNICATION

INFORMATION & DATA

INFORMATION CONTROL

COMMUNICATION ACROSS

CLEAR & CONSCISE INFORMATION

BENEFITS

INCREASED EQUIPMENT

AVAILABILITY

INCREASED OUTPUT

IMPROVED SAFETY &

ENVIRONMENTAL PERFORMANCE

OPTIMIZED MAINTENANCE COST

STATUTORY & REGULATORY

COMPLIANCE

CASE STUDY

PIPEWORK IN THE OIL & GAS

INDUSTRY

NOT AN INTEGRAL PART

INADEQUATE ATTENTION

NEGLECTED BY OPERATION,

MAINTENANCE & INSPECTION

LIFECYCLE OF PIPEWORK

FRAGMENTED APPROACH :

DIFFERENT GROUPS

PLANT TEAMS

SUPPLIERS

CONTRACTORS

FINDINGS OF HEALTH &

SAFETY EXECUTIVE

CUMMULATIVE EFFECT OF

COMPROMISES IN :

DESIGN

CONSTRUCTION

OPERATION

MAINTENANCE

ENSURE CO-ORDINATION

IDENTIFICATION

IMPLEMENTATION

SHARING EXPERIENCE

FRESH INITIATIVE

VULNERABILITY

DEFINE PRIORITY

INVESTMENT

QUESTIONS...

THANK YOU