PLANT INTEGRITY MANAGEMENT PRESENTED BY VIJAY VESVIKAR NDT Level III, CSWIP 3.1, API 570 MANAGER QA, NPC
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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
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