Kick Off Meeting Asset Integrity Management System

Kick Off Meeting
GTH Gas Processing Facility & Transportation Pipelines
Asset Integrity & Management System
22nd November, 2021
Velosi Project No: VISP-ISB-309-0921
Contract No: AMPCL/VELOSI/7100063512

A leading Asset Integrity, HSE and Engineering
Services provider to leading oil and gas companies
worldwide with 36 years of experience in oil and gas
industry.
We offer a full range of specialized engineering
consultancy services complete with our own in-
house proprietary software that has been developed
and tailored to the Energy business needs.

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Did you know?
Sometimes the most important work you can do is to
stop working.
If you're working and you see a process that is not
being followed correctly, or if you notice at-risk
behavior going on, take the initiative and call a quick
time-out.
Executing Stop Work Authority to right safety wrongs
and catch potential unsafe action before it actually
happens is not only responsible, it's also effective.
Empower the people around you. Encourage them to
watch for unsafe conditions or processes, and when
it's necessary, stop the job until it can be done safely.
Safety Moment & Exit Path

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Velosi Asset Integrity Services Introduction
Velosi Services
Project Objective
Scope of Work
CTRs Descriptions
Velosi Execution Methodology for CTR-01 to 12
CTR-01 (Development of Asset Register)
CTR-02 (Criticality Assessment of AIMS Assets)
CTR-03 (Risk Based Inspection Study)
CTR-04 (Development of Maintenance & Inspection Procedures)
AGENDA (1 of 3)
1
2
3
4
5
6
7
8
9
10

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CTR-05 (Development of Maintenance & Reliability Philosophy)
CTR-06 (Reliability, Availability & maintainability (RAM) model
development)
CTR-07 (Reliability Centered Maintenance)
CTR-08 (Enterprise Asset management Data Preparation)
CTR-09 (Operating Manuals & Procedures)
CTR-10 (SIL Classification & Verification Assessment)
CTR-11 (BOM & Spare Parts Optimization)
CTR-12 (Training Manual)
AGENDA (2 of 3)
11
14
15
16
17
18
12
13

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Project Schedule
Project Organization Chart
Project Progress Reporting
Minutes of Meeting
Communication Protocol
Document Review cycle
Project Quality & Information Manual (PQIM)
Need List
AGENDA (3 of 3)
19
20
21
22
23
24
25
26

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Velosi Asset Integrity Limited
Velosi Group was founded in 1982 in Malaysia
Velosi Asset Integrity Limited was founded in the UK in 2007 as part of the Velosi
Group of Companies.
We operate globally through our associate offices in Middle-East, Africa and Asia. Our
corporate office is in UK and Head office in UAE (Abu Dhabi). We have associated
offices in more than 38 countries worldwide.
A leading international consulting firm, currently enjoying the fastest growth rate
amongst our competitors.
Areas of Expertise

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Worldwide Existence of Velosi

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Velosi Services Coverage

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Asset Performance Management System (APMS)
Computerized Maintenance Management System (CMMS)
Safety Integrity Level (SIL)
Reliability Centered Maintenance (RCM)
Reliability Availability Maintainability (RAM)
Condition Based Monitoring (CBM)
Condition Assessment Studies
Asset Life Extension Studies
Corrosion Management Plan (CMP)
Corrosion Risk Assessment Study (CRAS)
DCVG & CIP Surveys
Technical Trainings
Our Services (1 of 5)
Risk Based Inspection (RBI)
Pipeline Integrity Management System (PIMS) - Onshore and Offshore
Structural Integrity Management System (SIMS)
Pressurized Equipment Management Systems (PEMS)
Inspection Scheduling Management System (ISMS)
Wellhead Integrity Management System (WHIMS)
Asset Integrity Management (AIM) Services

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Health, Safety and Environmental Services
HSEIA Studies
Process Safety and Risk Studies
 Workshop Facilitation
 Risk Assessment
 COMAH/Safety Cases
 Health Safety and Environmental Critical
Equipment Systems (HSECES)
 Drilling HSE Consultancy Services
Environmental Studies
 Environmental Impact Assessment (EIA)
 Environmental Management Plans (EMP)
 Environmental Compliance Audit (ECA)
 Environmental Modelling and Assessment (EMA)
 Environmental Monitoring and Testing (EMT)
Occupational Health Risk Assessment (OHRA)
 Emergency Management and Planning (EMP)
 Qualitative OHRA
 Quantitative OHRA
 Workplace Exposure Monitoring
 Industrial Hygiene Monitoring Plan

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Engineering Services
Conceptual Design FEED, Detailed Design and
Engineering Consultancy Services
Operating Manuals & Procedures
Design Verification & Appraisal
Fitness For Service (FFS)
As-Built Drafting Services
Software Solutions
VAIL-Plant (Asset Integrity Management System)
VAIL-PHA (Process Hazard Analysis)
VAIL-PSRA (Petrol Station Risk Assessment)
VAIL-MTS (Material Tracking System)
VAIL-ERP (Enterprise Resource Planning)
VAIL-CTR (Cost, Time & Resource Management)
VAIL-Flow (Approval Workflow Management)
VAIL-ORP (Online Reporting Portal)
VAIL-Feedback

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Audit & Assessments
OHSAS Safety Audits
Technical Audits
Environmental Audits
PSM Audits
Structural Audits
Firefighting System Adequacy Audits
Regulatory Compliance Audits
Flammable Storage Facility Audits
Electrical Audits
ISO Consultancy & Training
ISO 9001 - Quality Management System
ISO 14001- Environmental Management System
OHSAS 18001 - Occupational Health & Safety
Management Systems
ISO 45001 - Occupational Health & Safety Management
Systems
ISO 50001 - Energy Management System
ISO 55001 – Asset Management Systems

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Our training categories let you quickly select your chosen course and ensure you remain at the forefront of
developments throughout various industries.
o Certified Technical Training
o Exam Preparatory Training
o HSE Training
o Training in Oil and Gas Field
o ISO Trainings
Trainings & Certifications
o NEBOSH Training
o IOSH Training
o Administrative and Business Related Trainings
o Food Safety Training

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Velosi Clientele (Some of Our Clients)

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Velosi Certifications

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Velosi Accreditations and Approvals

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Velosi Memberships

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The main objective of this project is to:
Development of Maintenance and Asset Integrity Management System for green field project of
GTH facilities
Prevent integrity failures, loss of primary containment and avoid major accident hazard
To prevent or minimize consequences pertaining to health, safety, environment & production
outages due to breakdowns & unplanned downtimes to maximize ROI
To prepare standard maintenance procedures for efficient & effective Maintenance functions in
order to optimize field OPEX.
To ensure that assets deliver the required functions and performance in a sustainable manner to
achieve the system reliability and operational safety and to manage and mitigate deterioration
caused in assets
Project Objective

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Scope of Work
MPCL intends to engage services of a reputable company with min 10-15 year of experience in similar nature of
activities with renowned international Oil & Gas E & P companies for implementation of Asset Integrity
management System for green field projects & transportation pipelines.
The documentation shall be developed based on International Standards as mentioned in the SOW & recognized
practices
The main deliverables would be as under:
Development of Asset Register & BOMs
Criticality Assessment of Assets
Risk Based Inspection Study
Development of Maintenance & Inspection Procedures
Development of Maintenance and Reliability Philosophy
Scope of Work (1 of 2)

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Reliability, Availability and Maintainability (RAM) Model Development & Analysis
Reliability Centered Maintenance Study
Development of Operating Manuals and Procedures
Development of Training Manuals
Enterprise Asset Management (SAP) Data Preparation
BOM & Spare Parts Optimization
SIL Classification & Verification Assessment (Wells Only)
Scope of Work (2 of 2)
Scope of Work

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Velosi proposed following CTR’s to cover AIMS Project :
CTR-04 (Development of Maintenance & Inspection Procedures)
CTR-05 (Development of Maintenance & Reliability Philosophy)
CTR-06 (Reliability, Availability, Maintainability (RAM) Model Development)
CTR-07 (Reliability centered Maintenance)
CTR-08 (Enterprise Asset management Data Preparation)
CTRs Descriptions (1 of 2)
Scope of Work

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CTR-09 (Operating Manuals and Procedures)
CTR-10 (SIL Classification & Verification Assessment)
CTR-12 (Training Manual)
CTRs Descriptions (2 of 2)
Scope of Work

Velosi Execution Methodology for CTR-01
to12

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Scope of Work
Asset Register shall be prepared for Mechanical/Rotary, Electrical, PSV, Instrument, Static and rotary equipment,
Piping, PSVs etc in line best industrial practices/guidelines & ISO-14224 standard.
Scope of Work

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Velosi Approach
Following steps shall be used to develop Asset Register ,
Identification and evaluation of data
Identification of tags from collected documents like Equipment List, P&IDs, Single Line Diagram & Identification of
system, sub system, functional location and preparation of equipment hierarchy / boundary as per ISO-14224.
Identification of assets from the key project drawings (PFD, P&ID, Single line diagram, etc.) and assign asset
coding number as per Company guidelines.
Development of equipment SAP Location hierarchy
Populate the Engineering data in Asset Register, Identification of manufacturer, model and serial no. etc. from
available OEM manuals and data sheet.
Scope of Work

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Example of Asset Tagging, System Code and Engineering Data
Parent Tag No. Equipment Tag No. Equipment Description Equipment Type Equipment Class
11-71-0152G-CIS 11-71-P-152G-01
PUMP FOR CHEMICAL INJECTION
SKID 11-71-U-152G-01
Pump, Centrifugal P
System Code System Name Manufacturer Model No. Serial No. Design Press
A-ON-1171-WLGP Gas Production Well Head As per data
As per data
sheet
As per data sheet As per data sheet
Design Code CAPACITY (RATED Drawing Reference Data Sheet
API applicable code As per data sheet Reference doc. No. Reference data sheet no

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Equipment Boundary for Pump and Surface Wellhead as per ISO-14224 (1 of 6)

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Function Location and Equipment Hierarchy (5 of 6)
Hierarchy
Level
Location Label Functional Location Mask MPCL Company Plant System Unit
Main
Equipment
Main Equipment /
Equipment Sub Unit /
Child Tag 1
1 MPCL A A
2, 3 COMPANY A-ON ON
4 PLANT A-ON-1171 A-ON-1171
5 SYSTEM A-ON-1171-WLGP A-ON-1171-WLGP
6 UNIT A-ON-1171-WLGP-BB0152
A-ON-1171-WLGP-
BB0152
7 C-LOOP 11-71-0152G-CLPG
11-71-0152G-
CLPG
8 PIPING 11-8-PG-10000-251440-1
8 PIPING 11-8-PG-10001-251440-1
8 PIPING 11-1-PG-10000-251440-1
8 PIPING 11-1-PG-10001-251440-1
8 PIPING 11-6-PG-10041-091440-1
8 PIPING 11-4-PG-10041-091440-1
8 PIPING 11-1-PG-10266-091440-1
8 PIPING 11-1-PG-10150-091440-1
8 PIPING 11-8-PG-10001-091440-1

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Function Location and Equipment Hierarchy (6 of 6)
Hierarchy
Level
Location
Label
Functional Location Mask MPCL Company Plant System Unit Main Equipment
Main Equipment /
Equipment Sub Unit /
Child Tag 1
Equipment Sub Unit / Child Tag 1 /
Child Tag 2
1 MPCL A A
2, 3 COMPANY A-ON ON
4 PLANT A-ON-1171 A-ON-1171
5 SYSTEM A-ON-1171-WLGP A-ON-1171-WLGP
6 UNIT
A-ON-1171-WLGP-
BB0152
A-ON-1171-WLGP-
BB0152
7 SUB UNIT 11-71-0152G-WHCM 11-71-0152G-WHCM
8 SUB UNIT 11-71-0152G-WCFC 11-71-0152G-WCFC
9 TAG 11-71-CVA-152G-7000
9 TAG 11-71-FE-152G-1000
9 TAG 11-71-FT-152G-1000
9 TAG 11-71-FI-152G-1000A
8 SUB UNIT 11-71-0152G-WCFP 11-71-0152G-WCFP
9 TAG 11-71-PT-152G-3002A
9 TAG 11-71-ZSL-152G-7002A
9 TAG 11-71-ZSL-152G-7003A
8 SUB UNIT 11-71-0152G-WCAB 11-71-0152G-WCAB
9 TAG 11-71-PI-152G-4001
9 TAG 11-71-PT-152G-3006
9 TAG 11-71-SSV-152G-7004
9 TAG 11-71-ZSH-152G-7004B
9 TAG 11-71-ZSL-152G-7004A

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Scope of Work
After developing the asset register and identifying the assets on relevant drawings based on functionality, the next
step is identifying the criticality of the asset. The Criticality Assessment Standard details the minimum requirements
for doing the criticality assessment. The procedure for criticality determination and procedure for formation of right
team for doing the assessment must be ensured.
Asset Criticality Assessment shall be carried out at the Functional Unit level as defined in Asset register.
In addition to this Maintenance Criticality analysis will be carried out after identifying the Safety & Business Critical
Equipment.
Consequences including Safety, Health, Environment, Production / Operations, Asset and Company reputation shall
be considered for criticality analysis
Scope of Work

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Scope of Work
Spare parts classification based on criticality of equipment “Operability”.
Marking “ABC” indicator against each equipment tag in Annexure-D (SAP Equipment Master Template).
ECA will be carried out as per existing Risk Matrix implemented at MPCL. Consequences against Production Loss &
Capital Loss shall be defined by MPCL. However, same shall be deliberated with bidder team as well during
execution phase to make it in-line with prevailing practices in O&G.
Scope of Work

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Velosi Approach
Velosi shall follow the below mentioned approach to perform the Criticality Assessment of AIMS assets:
1) Review of Collected Data
2) Ranking of HSE and Business Critical Equipment and Systems (HSE&B-CES)
3) Categorization of Equipment (Catastrophic, Major, Moderate, Minor, Insignificant)
4) Preparation of Quantitative Criticality Assessment Data Base (QCA worksheet)
5) Criticality Ranking as per Risk Matrix
6) Submission of Quantitative Criticality assessment sheet with Report
7) Validation meeting with MPCL
8) MPCL review and comments
9) Incorporation of Comments
10) Submission of Quantitative Criticality Assessment sheet with Report

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Deliverables
Quantitative Criticality Assessment Sheet
Quantitative Criticality Assessment Report
Sample QCA Sheet
Sample QCA Report

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Scope of Work
Must establish the Risk Based Inspection program and provide the inspection plan for Static Equipment, Piping
and PSVs & shall perform semi-quantitative RBI Study for Static Equipment, PSVs and Piping System.
The main deliverable of RBI study must cover but not limited to:
i. Corrosion Loop Drawings
ii. Inspection Drawings
iii. Inspection Plan
iv. RBI Report
v. IOWs
Scope of Work

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Scope of Work
Sub-Semi-Quantitative RBI shall be carried out for following Asset Counts:
Scope of Work

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Velosi Approach for Static Equipment &
Piping
RBI Flow Chart for Static Equipment and Piping
System
Scope of Work
Start
Data Collection/Review and Asset Register
Preparation
Preparation of Corrosion Loop drawings
Threats and Consequences Assessment
Risk Based Prioritization Implementation Plan
Implementation of inspection plans
Data Gathering and review
Verification/Validation for Drawings and Document
Register
Identification of Assets for RBI Study
Preparation of Data Status
Identification of Operating Envelope and Operating
Conditions
Preparation of RBI Asset Register
Corrosion Rate Calculation
Remnant Life Calculation
Defining Corrosion Loops on PFD’s
Marking of Corrosion Loops on P&ID’s
Identification of Assets for each corrosion loop
Assessment of Confidence rating for each item and
degradation
Threats Assessment (Probability of failure)
Consequence Assessment (Consequence of failure)
Risk assessment per degradation mechanism
Implementation of inspection plans in inspection
management system
Implementation of RBI Inspection Plan in VAIL-Plant
Software
Preparation of Master Inspection Plan
Assessment of Inspection Intervals
Submissions
RBI Workshop

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Deliverables
The main deliverables of the RBI study will be:
Asset Register
Corrosion Loop Drawings
Inspection Plan
Inspection Drawings
Integrity Operating Windows (IOWs)
Corrosion & Inspection Strategy Document
RBI Report
Sample Corrosion Loop Drawing
Sample Inspection Plan
Sample Risk Based Inspection (RBI) Report
Sample Inspection Drawings
Sample CIS Document
Velosi will perform semi-quantitative RBI Study for Static Equipment and Piping System using
API 580/581/571 & VAIL Plant PEMS module under this CTR.
Scope of Work
Sample IOW

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FMECA based Risk Assessment Approach
for PSVs
Flow Chart for FMECA based Risk
Assessment for Pressure Relief
Devices (PSVs)
Scope of Work

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Deliverables
Asset Register
FMECA Sheet
Maintenance Plan for PSVs
Risk Analysis Report
Sample Asset Register
Sample Risk Analysis Report
Sample FMECA Sheet
Sample Maintenance Plan for PSVs
Velosi will performed FMECA based Risk Assessment study for PRDs using & VAIL Plant PSVMS
module under CTR.
Scope of Work

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RBI of Onshore Pipeline
Flow Chart for RBI Process for
Onshore Pipeline
Collection &
Review of Pipeline
Data
1. Pipeline Description
2. Basic Data
3. Operational Data
4. Profiles
5. Pipeline Layouts
Inspection history Survey
records (Event / log history &
Survey records)
Pipeline Assessment
No
Defect and RBI Assessment
Yes
Condition Assessment
Condition Monitoring
A) Metal Loss Defects
B) Defect Assessment
C) Inspection Results
A) Dent Assessment
B) Crack Assessment
A) Fluid Analysis
B) Weight Loss Coupon
C) ERP
Identification of Applicable Integrity
Threats/ Damage Mechanism
Mechanical Assessment of
pipeline and design verification as
per ASME B31.8 & B31G
Identification of High
Consequence Areas with respect
to health, safety and environment
Dividing the Pipeline into different
sections
Integrity Assessment
Risk Assessment
A) Probability of Failure
B) Consequence of Failure
Integrity Assessment
Development of Inspection Plan
Detailed Pipeline Assessment
Report
A) Selection of Indirect Inspections Tools
B) Assessment of Indirect Inspection results
C) Selection of Bell Hole (Direct
Examination) Locations
D) Carrying out selected direct inspection
techniques
E) Assessment of Direct Examination
Results
Portfolio Assessment
Scope of Work

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Deliverables
Section Layout Drawings
Mechanical Assessment Sheet
Inspection Plan for Onshore Pipeline
RBI report
Sample Section Layout Drawings
Sample RBI Report
Sample Mechanical Assessment
Sheet
Sample Inspection Plan
Velosi will perform RBI study for Onshore/Offshore Pipeline by Using API 580, 581, 579, 1163, B31.8, B31.4
& B31.8S (whichever is Applicable) & VAIL Plant PIMS module under this CTR.
Scope of Work

CTR-04 (Development of Maintenance &
Inspection Procedures)

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CTR-04 (Development of Maintenance
Procedures)
Scope of Work
Equipment specific maintenance & inspection plans & procedures for all equipment’s shall be prepared based on
RCM/RBI/RAM/SIL Studies, OEM guidelines and best industrial practices. Major Deliverables of this CTR shall include:
I. Equipment specific Maintenance & Inspection Procedures (as per list given below)
II. Maintenance & Inspection Strategy / Philosophy
III. Consolidated Maintenance & Inspection Plan
IV. Condition Monitoring Plans
V. Greasing & Lubrication Plans
VI. Inspection & Maintenance Checklists (Daily, QPMs, Cat A/B/C PMs, Log Sheets etc.)
Scope of Work

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Procedures)
Scope of Work
MPCL provided the list of 115 Inspection & Maintenance Procedures in SOW.
In addition to 115 x Procedures mentioned above, bidder shall keep the provision of additional 50 x Procedures which
may be required during project execution phase. Bidder shall keep the amount of these additional procedures in the
proposal.

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Procedures)
Velosi Approach (1 of 2)
Velosi shall develop the Maintenance Procedures under this CTR’s scope of work:
List of Maintenance & Inspection Procedures that shall be prepared for MPCL
Sample Maintenance Procedures

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Procedures)
Velosi Typical Approach (2 of 2)
Workshops with Company Engineers
1) Company's Corporate HSE
2) Company Focal Points (subject matter
experts);
i) Operators
ii) Maintenance Personnel
Collection of Documents:
1) Existing Procedures
2) Company Standards
Issuance of Gap Analysis
Report to Company
Feedback of Stakeholders
From:
Company
Issued for
Company Review
and Comments
Incorporation of Company
Comments
Approved
No
Forwarded to Step No. 2
For
Updating & Preparation of
Procedures
Review of Previous
Revision of Company
Procedures/ Standards
Review of Latest Revision of
Company Procedure/
Standards
Identification of Changes/
Updates in the Latest
Revision of Company
Procedure/ Standards
Yes
Compliance With
1) Company Specifications
2) Best Industry Practices
Issued for
Company Approval
STEP No. 01
Revise & Update
Existing Procedures
Develop
New Procedures:
Categorize All
Procedures
Updating Existing &
Preparing New
Procedures
Workshop with
Company
No
Yes
Incorporation of
Company Comments
(if any)
Submission for
Company Review
and Comment
Submission for
Company Approval
Approved by
Company
STEP No. 2

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Procedures)
Deliverables
Inspection & Maintenance Procedures (164 No.)
Shutdown Management Manual (01 Nos)

CTR-05 (Development of Maintenance and
Reliability Philosophy)

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Scope of Work
It is the policy of MPCL to optimize the life cycle cost of assets such that they maintain their intended capabilities in a
reliable, safe and productive manner. In doing so, due consideration is given to the following:
Adoption of a proactive maintenance and managing the consequences of failures.
Maintenance Strategy for each equipment unit shall be assigned in accordance with its criticality rating which will be
driven through formal risk assessment process
The Corporate Maintenance Management Manual CMMM would be the reference source for the maintenance
policy, maintenance framework, maintenance strategy and proactive workflow model.
Turn Around Management & Planning.
Scope of Work

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Velosi Approach
Velosi shall follow the below mentioned approach for the preparation of Maintenance and Reliability Philosophy :
Data Collection
Review of collected data
Development/Update of Maintenance & Reliability Philosophy
Internal QA/QC
Workshop / Meeting with MPCL
Submission of Maintenance & Reliability Philosophy Manual
MPCL Review & Comments
Incorporation of Comments
Submission of Maintenance & Reliability Philosophy for Approval

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Deliverables
Maintenance and Reliability Philosophy

CTR-06 (Reliability, Availability &
Maintainability RAM Model Development

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CTR-06 (RAM Study)
Scope of Work
To develop new Reliability, Availability, and maintainability Model.
i. RAM Analysis shall be conducted using RBD approach (Vendor may also propose their methodology for RAMS Analysis
including Monte-Carlo / Markov.)
ii. Collection and review of data (PFDs, P&IDs and OEMs Manuals etc.)
iii. Development of RBD.
iv. Create input data for the assessment of the Compression Package. That is, to provide data on failure rates of the system,
possible failure modes (based on machine history & OREDA onshore reliability database), Mean Time Between Failure,
Mean Downtime, maintenance operations, hazards & their consequences etc. Scope of Work

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CTR-06 (RAM Study)
Collection and review of data (PFDs, P&IDs and OEMs Manuals etc.)
Reliability Block Diagram (RBD) preparation
Calculation of Mean time to failure (MTTF) and Mean Time to repair (MTTR) by using valid data
Update the RBD with respect to reliability standard data source like OREDA or any other world class data source
acceptable for MPCL
RBD validation workshop
Evaluation of reliability and maintainability.

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CTR-06 (RAM Study)
Evaluation of availability and equipment capacity
Identification of bottlenecking and equipment criticality rank
Submission of RAM Study Report
MPCL Review & Comments
Submission of Final RAM Study Report

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CTR-06 (RAM Study)
Deliverables
System Hierarchy
Scope & System Boundaries for RAMS Analysis, & RBD
System FMECA
Details of Software Modules for RAMS Analysis
Input Data & Assumptions
Reliability Analysis, Availability Analysis, Maintainability Analysis
Safety Analysis
Calculations performed for RAMS Analysis
Sample RAM Study Report

CTR-07 (Reliability Centered Maintenance)

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CTR-07 (Reliability Centered Maintenance
Study)
Scope of Work
conduct an RCM study on all identified critical equipment through the Criticality Assessment & shall conduct an FMECA
study on all identified critical equipment through the Criticality Assessment.
Equipment Tags Count for RCM Study
Scope of Work

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Study)
Velosi shall carry out FMEA based RCM study by considering below mentioned activities;
Preparation of Asset Register (CTR-1)
Development of QCA(Quantitative Criticality Analysis) Study (CTR-2)
Development of Maintenance Criticality Assessment(MCA)
Identification of equipment boundary
Identification of function and function failure
Identification of Failure Modes
Listing and classification of failure modes (Classified as Critical, Degraded, Incipient)
Identification of failure effects to evaluate the consequences of failure on Safety, Environment, Production and Capital
Identification of Causes and Maintainable items

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CTR-07 (Reliability Centered Maintenance Study)
Development of Reliability Model Steps
o Calculation of MTBF and MTTR (Generic Data)
o Identification of POF & COF and Risk Calculation
o Risk analysis of failure modes against Safety, Environment, Production and Capital
o Identification of Active time to repair for each failure mode
Preparation of recommendations for Maintenance Strategy, PM Plans & Task Lists in MPCL FMECA and RCM templates
Submission of FMECA and RCM Sheets.
Validation workshop with MPCL
Final submission of FMECA and RCM Sheets

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Study)
Deliverables
Maintenance Criticality Assessment (MCA) Sheet
FMECA sheet
RCM sheet
Sample FMECA Sheet
Sample RCM Sheet
MCA Sheet

CTR-08 (Enterprise Asset Management Data
Preparation)

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Preparation)
Scope of Work
The Population of data in following SAP templates attached as Annexure-D/E/F/G/H/I/J at minimum:
- Equipment Master
- Object Parts,
- Causes,
- Damages,
- Tasks
- Activities & BOM
Scope of Work

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Velosi Approach
Meeting with MPCL SAP team to finalize the SAP templates , attributes and all necessary
data columns
Review of MPCL guidelines to prepare the SAP templates
Submission of SAP templates to MPCL for review and comments
Incorporation of comments and final submission
Populations of data in SAP Templates
Preparation)

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Deliverables
Filled SAP templates (07 No’s)
Preparation)
Sample Filled Templates

CTR-09 (Operating Manual & Procedures)

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Scope of Work
Velosi shall develop the Operating Manuals and Procedures under this CTR’s scope of work.
List of Operating Procedures that shall be prepared for MPCL
Sample Operating Procedures
Sample Operating Manuals
Deliverables
Operating Procedures (12+10 = 22 No.)
CTR-09 (Operating Manual & Procedures)

CTR-10 (SIL Classification and Verification
Assessment)

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Assessment)
Scope of Work
Velosi shall carry out the flowing activities:
• SIL Classification
• SIL Verification
For 12 Well Heads mention below.
Deliverables
• TOR for SIL study
• SIL Classification Report
• SIL Verification Report

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Assessment)
SIL Study
For this CTR VAIL PHA – SIL (Software) Will be used to carry out SIL Study activities which includes:
• SIL Classification
• SIL Verification
SIL Classification will be carried out by using LOPA Methodology by using VAIL PHA - SIL
SIL Verification will be carried out by using simplified equations by using VAIL PHA – SIL
For further details, please refer to detailed
SIL Study presentation
Velosi Approach for SIL Study

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Scope of Work
Development of Inventory List against RCM/RBI/SIL/RAM studies.
Classification and ABC Categorization of Spare parts
Assessment of the criticality rating of each item from both maintenance engineering and an application point of view
Identification of location and holding of the spares by using risk model
Assessment of the spare parts required to support the maintenance plan to set the minimum & maximum levels as
per safety & economics requirement
Recommendations for MIN / MAX levels for spares (as per format attached in Annexure-N), Re-Order points and
Economic Order quantity(EOQ)
Assessment of slow and fast moving stock at re-order point
Identification of excessive stock levels & subsequent elimination of un-necessary spares, leading to lower operating
costs & release of tied-up capital
Scope of Work

SLIDE No. 84 OF 99
Scope of Work
Preparation of Equipment Specific Spare Parts List.
For defining description of spares, MPCL existing nomenclature shall be used. Nomenclature will be shared during
Project Execution.
The deliverables mentioned above shall be provided in both native files (excel, word) & pdf formats wherever
applicable.

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Velosi Approach
Sample BOM

SLIDE No. 87 OF 99
CTR-12 (Training Manuals)
Scope of Work
Consolidated Training Manual shall be developed for Operation & Maintenance Staff of GTH Facilities. Training Manual
shall cover section 6 (sub section: a to i & k to n) with focus on maintenance, inspections & troubleshooting. Training
Manual shall include minimum of following training Modules
Introduction
Objectives
Key Definitions
Training Module to Update Asset Register
Training Module for Criticality Assessment of Assets
Training Module for Inspection & Maintenance Procedures
Scope of Work

SLIDE No. 88 OF 99
Scope of Work
Training Module for Operating Manual & Procedures
Training Module for RBI
Training Module for RCM
Training Module for RAM
Training Module for SIL
Training Manual for Maintenance & Reliability Philosophy
Troubleshooting Guidelines
Performance Management
Competency Requirements

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Velosi Approach Project Kick-off Meeting
Project Flow Chart for Main Activities
Working Methodologies
 Preparation of working methodologies and
outcomes of individual CTRs
Submission of Documents to Company Rev.A
Company Review & Comments
Internal QA/QC
and IDC
Development of Training Manual
 Combining of all working methodologies and
outcomes of individual CTRs
Workshop on Rev.A
Submission of Rev. B Documents to Company after Comments
Incorporation
Workshop on Rev.B
Company Review & Comments
Final Submission of Documents to Company after Comments
Incorporation

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Deliverables
Training Manual (01 No’s)

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Project Schedule
Project Schedule
Milestone dates are as under:
Effective date of contract 22nd November, 2021
Project Duration 8 months
Phase-1 29th January, 2022
Phase-2: 14th May, 2022
Phase-3: 18th June,2022

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SLIDE No. 93 OF 99
Progress Report
Progress Report

SLIDE No. 94 OF 99
Sample MOM
Minutes of Meeting

SLIDE No. 95 OF 99
From Velosi
1. Mr. Ijaz Ul Karim Rao (Project Manager )
2. Ms. Mubeena Khatoon (Manager-Engineering Services)
3. Mr. Sarmad Shamim (Project Coordinator)
4. Mr. Kamran Ibrahim (Operations Manager)
5. Mr. Imran Saeed (Head of RBI Services)
6. Mr. M Shehzad (Project Engineer)
7. Mr. Hassan Rasheed (Integrity & Reliability Manager)
8. Mr. Khalid Mehmood (Document Controller)
Project Communication
Project Communication
Protocol
• MPCL to advise about the team members which shall be
included in email communications.
From MPCL

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Document Review Cycle

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Project Quality and Information Manual (PQIM)
For details Velosi Project Quality and Information Manual (PQIM) can be seen at:
Project Quality and Information
Manual (PQIM)

SLIDE No. 98 OF 99
Need List
Need list regarding data requirement is prepared and shared with MPCL . Any data requirement raised
during the project phase will be conveyed to MPCL
Need List

Kick Off Meeting Asset Integrity Management System

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