statoil insulation requirements and the effect on total...

1 - Overflate 2015 / Frode A. Kvilhaug

Statoil insulation requirements and the effect on total project cost Frode A. Kvilhaug Leading Advisor Surface Protection and Polymer Materials Statoil

Agenda:

•  Statoil experience on what factors driving up the cost in projects?

•  What can be done to challenge this cost increasing factors?

•  Qualification and competence activities internally in Statoil

•  TR1660 - Piping and equipment insulation – What is new?

•  Expected results from the activities and new technical requirements?

2 Overflate 2015 / Frode A. Kvilhaug

Statoil experience on what factors driving up the cost in projects

•  Insulation is handled late in the project – During construction phase

− Not optimal design

− No time for critical evaluation of where and how much to insulate

− Activities controlled by the insulation contractor

•  Lack of insulation competence in the project

− All activities and planning run by the insulation contractor

−  Insulation based on supplier not general solution

− No critical review of the insulation work

•  Lack of implementing all relevant disciplines in the insulation scope


Insulation SOW

Process

Technical safety

Work environment

Knock on effect on: •  Supports •  Space •  Coating •  Weight •  Engineering and construction •  Follow up •  Operations - CUI

Instrument

Architect

“More effort on challenging the insulation scope, investigating and implementing smarter technical solutions could also have had significant impact.” – project experience report

Insulation

HVAC

Overflate 2015 / Frode A. Kvilhaug 4

Lack of knowledge about the technical requirements?


Requirements and best practice related to insulation and CUI management in Statoil

6

Insulation

TR1660 Piping and equipment insulation

NORSOK R-004 Piping and equipment insulation

Weather protection

TR1660 Piping and equipment insulation

Other requirements

TR3102 Materials Selection for Development and Modification Projects

TR3016 Piping repair and cold installation methods

Safety/acoustic requirements

Inspection and maintenance TR1660 Piping and equipment insulation

TR0007 Requirements for coating Maintenance

TR1987 Program activity requirements for static process equipment and load-bearing structures

GL0560 Prioritering av vedlikehold for statisk prosessutstyr utsatt for korrosjon under isolasjon

TR2391 Preventive activities requirements for Rigid Pipeline Systems

TR2392 Program Activity Requirements for Flexible Pipelines

Coating

TR0042 Surface preparation and protective coating

TR0007 Requirements for coating Maintenance

Norsok M-501 Surface preparation and protective coating

Overflate 2015 / Frode A. Kvilhaug

What can be done to challenge this cost increasing factors?

•  Introduce the insulation scopes earlier in the project

•  Higher focus in the projects on the insulation discipline

•  Increase competence in the company/projects

− Workshops

− Multi discipline collaboration meetings

− Meetings with suppliers/contractors

− Core group meetings

•  Challenge the “known facts”

− Study documentation from suppliers, papers etc.

−  Internal testing

•  Implement the achieved knowledge into Technical Requirements.


Qualification and competence activities internally in Statoil

• Corrosion under insulation project and workshops

• Supplier meetings

• Passive fire protection multidiscipline internal project

• Workshops insulation and PFP

• Bi-monthly core group meetings

• Communication through internal network

• Communication of the requirements internally

• Testing in Porsgrunn


TR1660 - Piping and equipment insulation

What is new?


More prescriptive requirements

•  Type of qualified insulation material

•  Type of sealer and gasket material – App C


More prescriptive requirements

•  New solutions are subject to a written approval by Company

− Company in charge of what being approved.

•  New solutions for use of bolt protection for passive fire protection given in Insulation Handbook


TR1660 - What else is new?

•  Insulation Handbook now a part of the document – Easier access for contractors


Early focus on insulation in projects

•  An insulation philosophy shall be established in the FEED phase.

•  An insulation strategy and material selection report shall be established and form the basis for the detailed engineering and selection of insulation materials

•  A construction strategy for insulation shall be developed


Early focus on insulation in operations

• A construction strategy for insulation shall be developed

• Selection of materials shall be documented in a Material Selection Report


What is the expected results from the activities and new technical requirements?


Lower weight of facilities

•  Slimmer design

•  Lower weight of insulation solutions

•  Less insulation


No corrosion under insulation (CUI)

•  Less insulation – Less possible CUI areas

•  Good workmanship – More correct solutions

•  Using only approved products and solutions – Tested for best resistance towards CUI

•  Better insulation competence – Better total understanding and monitoring of the insulation work.


Other expected results from the activities and new technical requirements

•  High status for insulation work and thereby focus on insulation requirements

•  Less time used in discussions with contractors over requirements and deviations

•  Greater knowledge internally (and externally) will result in better decisions.


Conclusion

Early focus on insulation

Correct on the requirements

Greater insulation knowledge

No CUI

Saving weight

Saving cost (Capex and Opex)



Frode A. Kvilhaug, Statoil ASA Leading Advisor Surface Treatment and Polymers

[email protected] mob: +47 48 26 13 61

www.statoil.com

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