7/30/2019 Ray Goodfellow
1/26
Incorporating an Asset
Integrity Program into the
Design Stageof Projects
Ray GoodfellowPangea Solutions IncMay 9, 2008
mailto:[email protected]:[email protected]7/30/2019 Ray Goodfellow
2/26
What is Asset Integrity Asset Integrity is an effective system for
managing the integrity of equipment, piping andpipelines throughout the full lifecycle: design
construction & installation operation
maintenance, (repairs, alterations)
integrity assessments
decommissioning
Developing and implementing an Asset Integrityprogram at the design stage supports lifecyclereliability and operability
7/30/2019 Ray Goodfellow
3/26
What is Asset Integrity Regulatory Requirements (ABSA/CSA/EUB/)
Pressure Equipment Integrity Management System(PEIMS)
Pipeline Integrity Management Program
Key elements include:Risk assessments
Degradation Circuits
Material selection
Condition monitoring location (CML) selection Inspection, Mitigation, Monitoring
Data management
Training programs
7/30/2019 Ray Goodfellow
4/26
What is Asset Integrity
Typical Equipment within Scope: Boilers and heaters
Pressure vessels (including Pressure relief devices)
Pressure piping
Tanks Non-pressure static equipment
Non-pressure piping
Pipelines
Not in Scope Structural
Rotating equipment
Electrical
7/30/2019 Ray Goodfellow
5/26
Overview
Why:
What is the value of incorporating Asset Integrity into
the design stage of a project?
How:
What are the key activities at each stage of the
project?
Deliverables: What are the deliverables at each stage of the
project?
7/30/2019 Ray Goodfellow
6/26
7/30/2019 Ray Goodfellow
7/26
Why
De-ethanizer overhead gas
line
erosion corrosion
failure downstream of mixing
point
Humber Refinery Fire, Health Safety Executive (HSE) Report
http://www.hse.gov.uk/offshore/information.htm\
http://www.hse.gov.uk/offshore/information.htm/http://www.hse.gov.uk/offshore/information.htm/http://www.hse.gov.uk/offshore/information.htm/7/30/2019 Ray Goodfellow
8/26
Why incorporate Asset Integrity into
the design stage of a project The goal of each project is to create a business asset
that performs its intended function, is safe,environmentally sound and reliable. The project is expected to be executed within the planned cost
and schedule
* I cant emphasize enough that youve got to get this right.You got to get this right. Because when you finally lock thescope, youre stuck with it for 30, 40, 50 years, so you betternot have any regrets when you start building it and running itthat you didnt get it right
~Neil Camarta
*Petro-Canada Investor Day: Fort HillsOil Sands Engine of Growth, Neil Camarta, Senior Vice-President, OilSands
7/30/2019 Ray Goodfellow
9/26
You got to get this right
Incorporate lifecycle asset integrity into the
design
Have a positive impact:
for the project efficient project execution
and optimize capital costs
for the operation- improve reliability andoperability
7/30/2019 Ray Goodfellow
10/26
Incorporate lifecycle asset integrity into
the design Make well thought out
decisions to meet project
and operations objectives
Good decisions include:
Involving the right people
Having a structured process
to guide decision making
Maintaining good
documentation
7/30/2019 Ray Goodfellow
11/26
Incorporate lifecycle asset integrity
into the design Increased upfront engineering can:
Support quality decisions regarding CAPEX (design
mitigation) and OPEX (operational mitigation) Provide clarity and direction that reduces time in
detailed engineering
Reduce rework during fabrication and during
operationsMeet operational reliability expectations for long term
plant life
7/30/2019 Ray Goodfellow
12/26
Trend in Industry
Understanding of the importance ofincorporating Asset Integrity into the designstage is increasing due to serious failures in the
refinery, petrochemical and pipeline industryMajor corporations now require risk assessments at
the design stage.
Regulator requires the effective systems formanaging the integrity of their pressure equipmentthroughout its full lifecycle which includes design,construction and installation.
7/30/2019 Ray Goodfellow
13/26
How
Incorporate asset integrity activities into key
phases of the project
Identify key project objectives, development phases,
milestones and hold points Utilize defined processes (i.e. Risk Base Inspection)
to make decisions
Supply defined deliverables at each stage of the
projectRecognize, understand, and quantify the impacts and
values added from asset integrity activities
7/30/2019 Ray Goodfellow
14/26
Key activities and deliverables at
each stage of the project Companies have multi step project
management processes
1. Select Alternatives2. Front End Engineering
3. Detailed Engineering
4. Fabrication and Construction
5. Commissioning6. Turn Over to operations
7/30/2019 Ray Goodfellow
15/26
1. Select Alternatives
Key ProcessesDesign Basis Risk Assessment
Lessons Learned Study
Key DeliverablesAsset Integrity design philosophy report
Lessons learned report
Technical work book with all supporting
information. (dynamic document) The work book will form the basis of additional risk
assessments and the integrity manuals for theoperating facilities
7/30/2019 Ray Goodfellow
16/26
1. Select Alternatives Impact
Business basis for integritymanagement strategy
Risk based decisions thatconsider full asset lifecycle Design mitigation
Alloys, coatings, equipmentdesign, process changes
Operational mitigation Inhibition, process control,
inspection, monitoring, run to
failureAlternative selection considers
potential degradationmechanisms and otherhazards
7/30/2019 Ray Goodfellow
17/26
2. Front End Engineering Key Activities
Risk Assessment
Incorporate lessons learned
Development/Updating of Standards
Management of Change Key Deliverables
Scope and budget includes asset integrity and QAwork
Technical work book with all supporting information.
New or revised specifications
Documented basis of integrity related designdecisions
7/30/2019 Ray Goodfellow
18/26
2. Front End Engineering
Impact Scope and costs for integrity
related work are included inproject budget
Determine first plannedshutdown Equipment isolation and
inspection plan
Design mitigation
i.e. select materials and designOperational mitigation
i.e. select mitigation andmonitoring strategy
7/30/2019 Ray Goodfellow
19/26
3. Detailed Engineering Key Processes
Assessment of deviations from initial design Previous Risk Assessment methodology can be used
Materials selection report and diagram (MSD) reviews
P&ID reviews
Development/Implementation of quality assurance program
Key Deliverables
Reports or recommendations on specific technical issues Equipment Integrity Manuals
Based on technical work books
Degradation circuits
Document the basis of design decisions
Incorporates information from reports or recommendations on specific
technical issues Foundation of RBI and overall asset integrity program
Incorporate EPC Information
Condition Monitoring Location (CML) selection
Corrosion monitoring locations
QA issues
7/30/2019 Ray Goodfellow
20/26
3. Detailed Engineering Impact
Provide technical input atproject reviews, hold points,and milestones
Capture the technical basisand rational behind material,mitigation, monitoring andinspection decisions Understanding the rational
allows more effectivemanagement of future changes(personal and process)
3D Modeling can be used forselection of CMLs, corrosionmonitoring locations, etc.
7/30/2019 Ray Goodfellow
21/26
4. Fabrication and Construction
Key ActivitiesQuality assurance and Quality control
a key aspect of asset integrity
Vendor audits and reviews
Assessment of deviations from design
Key Deliverables Updated equipment integrity manuals
Baseline CML survey on critical equipment and pipingcompleted
Start populating equipment data base
7/30/2019 Ray Goodfellow
22/26
4. Fabrication and Construction
Impact
Final product
meets design
specifications
Have base line
data
7/30/2019 Ray Goodfellow
23/26
5. Commissioning Key Activities
Assessment of deviations from design
Regulatory requirements prior to start up
Plan for start up activities
Key Deliverables Installation Inspections compete
PSVs serviced
Equipment integrity manual complete
Equipment database is populated with new equipment
Baseline TML complete on critical equipment and piping
Complete training for critical tasks
7/30/2019 Ray Goodfellow
24/26
5. Commissioning Impact
All critical tasks have
been completed prior
to start up
Installation inspections
and PSV servicing Inhibition programs in
place
Monitoring programs in
place
Training on procedurescompleted
7/30/2019 Ray Goodfellow
25/26
6. Hand Over to Operations
Key Processes Training
Key Deliverables Equipment Integrity Manuals
Documentation of deviations from design
Populated database
Mitigation and monitoring planMaintenance planning
Long term training program
7/30/2019 Ray Goodfellow
26/26
6. Hand Over to Operations Impact
A business asset that is safe, environmentally sound and reliable
http://www.chemicals-technology.com/projects/safco/index.html