Webinar | GE & Stork | APM Best Practices - Mechanical Integrity
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Slides used in the webinar by GE Digital and Stork on Best Practices in Asset Performance Management - focus: Mechanical Integrity
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Webinar | GE & Stork | APM Best Practices - Mechanical Integrity
- 1. Plaatje leaflet hier invoegen The webinar starts at 12.00h CET You can ask questions through the Q&A button in the Zoom menu During the webinar all participants are on ‘mute’. MECHANICAL INTEGRITY
- 2. Asset Performance management – Best Practices With ever-increasing safety and environmental constraints, it is critical that operators can ensure the safe operation and containment of their processes. Mechanical integrity regulations require a significant amount of data be captured to ensure process equipment is designed, fabricated, installed, operated, and maintained properly to mitigate associated risks. This generates a significant amount of data that companies must manage; making it increasingly difficult to understand current risk levels and drive optimization of mechanical integrity inspection and engineering resources. Automating this process is the next obvious step – but to achieve this next level of optimization, companies need expert insights on legal requirements, innovative solutions and seamless implementation. During this first in a series of webinars, GE Digital and Stork share their insights as APM solution provider and system integrator. We will present recent best practices client cases for APM implementation and share insight into changing German legislation on inspection requirements. - overall narrative -
- 3. Program 12.00 – 12.15 an introduction to apm and mechanical integrity Hans Minnaard 12.15 – 12.30 enabling german 'betrsichv' regulatory requirements with apm Vipin Nair 12.30 – 12.45 successful implementations at freeport lng and socar Luciano Narcisi 12.45 – 13.00 panel discussion Johan Ferket There will be poll questions after each presentation and we will discuss the results during the panel discussion together with your specific questions.
- 4. Introduction of speakers Hans Minnaard Principal consultant Stork Asset Management Technology Luciano Narcisi Senior Consultant Stork Asset Management Technology Vipin Nair Senior Product Manager APM Integrity solution - GE Digital
- 5. APM Best Practices seminars High overview introduction • Full integrated APM solution Best Practices Application Cases Open table • Open table with attendees related with the application example Mechanical Integrity and compliance Reliability Added Values Maintaining your Safety Integrity Levels Asset Strategy Library
- 6. The Partnership Clients Accelerated Adoption + Time to Value + Sustainable ROI Market Leader in Asset Performance Management Technology & Services World Class Functional Asset Management Solutions
- 7. How Stork Accelerates Your APM Adoption o Planned / Preventive / Predictive / Prescriptive Maintenance Strategies o Lean and Performance Based Maintenance programs o Reliability Centered Maintenance (RCM) o Risk Based Assessment (RBA) o Reliability, Availability & Maintainability (RAM) analysis APM Software and Continuous Improvement Work Processes o Inspection and integrity services to manage risk, reduce failures and increase asset life o Reliability engineering services o Evergreen your approach o Asset management performance modeling (objectives and KPIs)
- 8. Asset Reliability and Integrity Management Model Stork together with GE Digital are the best partners in Asset Performance Management. Through an integrated approach, we can support our clients to improve their overall Asset Performance Management. Through this seminars, we would like to show and discuss best practices application examples related to Asset Performance Management.
- 10. APM Best Practices – Mechanical Integrity We will describe three different application examples to show the benefit of implementing a sustainable Mechanical Integrity system, in relation with government requirement inspections. • Enabling German 'betrsichv' regulatory requirements with APM • Freeport LNG: Excellence in Fixed Asset Integrity Management • SOCAR: adjusting government requirement inspections through RBI Natural Gas Liquefaction plant, Texas, USA Refinery and Petrochemical plant, Aliağa, Turkey Enabling german 'betrsichv' regulatory requirements with apm
- 11. Poll question 1. Is RBI accepted in your country to optimize the inspection effort related to risk? • Yes • No 2. Are you able to create windows of opportunity to execute inspection tasks with different frequencies? • Yes • No
- 12. Compliance Management – Why? Challenge • Very few safeguards exist within most companies today to ensure regulatory inspection requirements are met on all applicable in-service equipment • Time intensive to implement or evergreen regulatory inspection strategies in IDMS system’s today • If new equipment is put-in-service (input to EAM/CMMS system) – reliant on manual processes to implement the correct inspection strategy in IDMS Global Requirements • Ability to define templates for various standards like API, German/ Dutch regulation, Australian regulation, state regulations, etc. • Automate existing inspection data management system framework and workflow • Configurable framework for users to automatically suggest inspection strategy based on local or geographical statutory regulations when new assets are loaded into EAM and IDMS
- 13. Current Inspection Planning Workflow EAM / CMMS Inspection Data Management System Inspection Planning • Functional Location/ Asset ID • Master Equipment Data • Inspection Tasks • Inspection Execution • Inspection and Corrosion History Plan Schedule Compliance 1,000’s of inspection / corrosion tasks Documented Compliance Manual Process
- 14. Proposed Inspection Planning Workflow EAM / CMMS Inspection Data Management System Inspection Planning • Functional Location/ Asset ID • Master Equipment Data • Inspection Plans • Inspection Execution • Inspection and Corrosion History 1,000’s of inspection / corrosion tasks Documented Compliance Automated inspection plans based on regulatory code Approval / Review
- 15. German (BetrSichv) Inspection In Germany, inspections of pressure-containing assets are regulated by the industrial safety regulation (betrsichv). The aim of this regulation is to guarantee the protection of employees' health and safety when using work equipment. European inspections can recommend applicable inspection task types along with recommended interval based on each asset type This module will also help you identify the certification requirements of inspectors. For example, züs (approved inspection body) and bp (qualified person) based on the criticality of the asset. the certification requirement is as government regulation based on pressure, volume, and fluid characteristics
- 16. Inspection Strategy and Certification as per BetrSic
- 17. APM Best Practices – Customers
- 18. Demo - Asset Technical Data and Certification Calculation Demo
- 19. Demo - Compliance Strategy templates Demo
- 20. Demo - Automated inspection plan as per template Demo
- 21. Demo - Inspection Plan Demo
- 22. Demo – Bulk Operations – Quicker time to value Bulk approval Bulk implementation
- 23. Poll question 1. Do you use or are you considering to implement a solution that can integrate inspection compliance, RBI methodology and other APM methodologies? • We are already using one • We are considering to implement one • None 2. In what way do you think GE Digital German development could be applicable in your Country? • Fully applicable • Partially applicable • Not applicable
- 24. APM Best Practices – Mechanical Integrity • Freeport LNG Liquefaction Project selected GE Digital APM software V4 to support Mechanical Integrity system implementation in Dec. 2015. • Stork Technical Services USA was selected to implement the software and conduct the baseline Mechanical Integrity System implementation project. Excellence in Fixed Asset Integrity Management at Freeport LNG
- 25. APM Best Practices – Mechanical Integrity • Scope included: − Risk assessment − Thickness Monitoring Location definition − Inspection management − Execution of RBI Inspection plan − Structures and lifting equipment inspection • More than 3000 pipes • 600 major equipment • Through this initiative, Freeport was able to provide evidence from risk mitigation standpoint, in order to extend government requirement inspection intervals from 1 to 5 years Excellence in Fixed Asset Integrity Management at Freeport LNG
- 26. APM Best Practices – Mechanical Integrity • In June 2018 Socar started a full APM Implementation project supported by GE Digital APM software (APM Foundation/Reliability/Safety and Mechanical Integrity). • Stork was selected as the APM partner to build a solid foundation to ensure a sustainable implementation. Stork is able to support clients with integrated solution. Challenges: • Implement best practice on a green field and brown field plants at the same time • COVID-19 SOCAR Turkey Extends Mandatory Inspections Period and Achieves World Class Asset Integrity with GE Digital APM and Stork
- 27. APM Best Practices – Mechanical Integrity Mechanical Integrity scope included: • Risk-Based Inspection (RBI 580 & RBI 581) • Inspection Management • Thickness Monitoring • Asset Health Management (Integrity Operating Windows) Greenfield refinery 214.000 bbl./day Pilot plant LDPE-T • Through this initiative, SOCAR was able to adjust government required inspection from yearly hydrostatic test to five year interval inspections with a scope adjusted based on RBI recommendations. SOCAR Turkey Extends Mandatory Inspections Period and Achieves World Class Asset Integrity with GE Digital APM and Stork
- 28. APM Best Practices – Mechanical Integrity • How is it possible to extend inspection intervals by applying RBI? 1st: RBI is not a tool to extend inspection intervals, it’s a methodology to define value added inspection strategies. RBI as the prefer methodology to design cost effective inspection strategies
- 29. RBI: methodology to design cost effective inspection strategies • How is it possible to extend inspection intervals by applying RBI? Gathering, reviewing, organizing data and understand what is missing Understanding Potential Damage Mechanisms and their severity Assessing the risk to each RBI component Defining risk based inspection strategies Defining alternative mitigation actions such as IOW Keeping the Mechanical Integrity system updated
- 30. How Stork & GE Digital help to implement a sustainable Mechanical Integrity System? Keep management involved Weekly report Business cases Plan in advance and define resources, roles and responsibilities. Project Gantt Project Initiation Document Weekly report Clear and simple process guides MI Process Guides aligned with GE APM Training based on Process Guides Search and communicate quick wins and business cases Business cases were prepared and shared with team Articles and white papers Perform trainings, train the trainer APM Training Basic Training Extensive training Add Team members training Technology usage to support the system GE APM Empower the end user and make them own the system Cases were presented by end user, with our support Results validated through RBI workshops Define Integrity Champions Champions clearly identified Champions matrix SUSTAINABLE IMPLEMENTATION
- 31. Poll question 1. What kind of benefits do you see in having an integrated APM software solution? (multiple answers) a) Facilitates demonstrability during audits b) Increases the synergy of APM efforts c) Optimize APM processes d) Increases APM system effectiveness e) No benefits 2. What is the highest value within an RBI implementation? a) Helps to find the weakest link in the chain b) Enables you to identify your most critical components c) Helps you to design cost effective inspections
- 32. APM Best Practices – Mechanical Integrity Questions Via Q&A Or get in touch with our host: Johan Ferket Johan.Ferket@stork.com +32 473 864 083
- 33. Plaatje leaflet hier invoegen THANK YOU FOR YOUR ATTENTION
Editor's Notes
- Hans Minnaard will introduce the concept of Asset Performance Management and the various domains leading to more efficiency and long term success for your organization. In this webinar he focusses on foundations for Mechanical Integrity in an Asset Management journey. He explains the various roles in this process and the benefits of an integrated approach for APM solutions. As a prelude to best practices he describes the concepts behind the application examples. Vipin….. describe Vipin’s Luciano Narcisi will guide you through two examples of successful APM implementation focused on mechanical integrity. At SOCAR in Turkey, Stork and GE Digital channeled a journey that enabled SOCAR to extend the mandatory inspections period by adjusting government inspection requirements through RBI. At Freeport LNG, Stork was selected to build the foundations for a Mechanical Integrity System. Together with GE Digital, we helped the client maintain the asset's integrity and ensure operational safety while extending government requirements for inspection intervals. Insight into changing German legislation on inspection requirements.....
- Hans Minnaard will introduce the concept of Asset Performance Management and the various domains leading to more efficiency and long term success for your organization. In this webinar he focusses on foundations for Mechanical Integrity in an Asset Management journey. He explains the various roles in this process and the benefits of an integrated approach for APM solutions. As a prelude to best practices he describes the concepts behind the application examples. Luciano Narcisi will guide you through two examples of successful APM implementation focused on mechanical integrity. At SOCAR in Turkey, Stork and GE Digital channeled a journey that enabled SOCAR to extend the mandatory inspections period by adjusting government inspection requirements through RBI. At Freeport LNG, Stork was selected to build the foundations for a Mechanical Integrity System. Together with GE Digital, we helped the client maintain the asset's integrity and ensure operational safety while extending government requirements for inspection intervals. Insight into changing German legislation on inspection requirements.....
- Hans Minnaard – Principal consultant Stork Asset Management Technology. Hans is principal consultant in the field of Asset Performance Management and is the competence leader in various GE Digital APM software selection and implementation projects. His passion is to coach people to strengthen their ability to deal with the challenges in their daily life at work. As a trusted advisor he supports clients in O&G and Chemicals in projects with a strong change management component. Hans holds a Bachelor degree in Electrical Engineering and a Master degree in Organizational Change Management. Luciano Narcisi - Senior Consultant - Stork Asset Management Technology Luciano is a mechanical engineer with a master degree in risk and reliability. With more than 10 years of experience in Mechanical Integrity Management, he specialized in Risk Based Inspection methodology and implementation of Mechanical Integrity systems in the Oil & Gas industry. He had the opportunity to lead projects in different contexts: downstream and upstream, offshore and onshore, greenfield and brownfields operations in South America and Europe. Currently working as a Senior Consultant at Stork AMT, he is supporting clients to implement sustainable APM systems. Vipin Nair - Senior Product Manager, APM Integrity solution, GE Digital With more than 14 years of experience in Asset Performance Management, Vipin Nair is product leader for GE APM Integrity, delivering high-value product solutions and managing the overall product life cycle of fixed and linear assets. He joined Meridium in 2012 and has served the needs of customers through various roles in consulting, pre-sales and product management. Vipin’s previous experience includes reliability and maintenance positions with a major corporation in the process and manufacturing industry. Vipin holds a Bachelor of Technology in Mechanical Engineering, is an active member of the API 581 task force group, and holds several active API certifications like API 580, 571.
- This is a bit more of a granular view of the GE Digital Continuous Improvement framework and how the entire suite of software holistically works together. This gives you an idea of all the different functions and work processes the Asset Performance Management solution can enable. For today's discussion we will be focused on the maroon portions of this visualization specific to Mechanical Integrity. In subsequent seminars we will cover additional work processes and functions and how GE Digital’s solutions and stork best practices can be leveraged in your organization. Today we will take you through several case studies that discuss how the GE Digital APM Integrity solution and Stork best practices enable organizations to calculate risk, inspection priority, and the remaining useful life of assets to generate, implement, and execute optimized inspection plans, while streamlining auditability and compliance governance. As I said we also have Vipin Nair, Product Manager for the APM Integrity Solution at GE Digital who will dive into this box called regulatory requirements. Vipin will cover some relatively new functionality GE Digital has developed specifically around the inspection planning process and enabling quick time to value for customers needing to comply with EN code requirements.
- Following, we will describe three application examples that show the benefits of applying APM methodologies. In these cases, we will focus on RBI application, and how it was used to adjust government required inspection. (click) First, we will present the new tool developed by GE Digital to manage compliance and it application to the German legislation. Then, we will describe two projects where the client was able to adjust government required inspection based on RBI approach: (click) A Mechanical Integrity implementation for a liquefaction plant operated by Freeport LNG in Texas, USA (click) A full APM project including Mechanical Integrity for a refinery and petrochemical unit in Turkey, operated by SOCAR
- As we saw with BetrievsSicherheit, Mechanical Integrity is usually covered by government regulations. But how can APM approach help us on this matter? The following examples show how the clients were benefited through the implementation of RBI. In December 2015, Freeport selected GE Digital to support the mechanical integrity system implementation, and choose Stork Technical Services in USA to help building the foundation for a sustainable mechanical integrity system. During the implementation, GE Digital APM proved to be adaptable to multiple types of assets, fluids, operating conditions, risks analyses and inspection requirements and the excellent support from GE Digital was always forthcoming.
- The scope of work in the Freeport LNG project included: Risk assessment using the RBI Criticality tool, aligned with API 580 Thickness monitoring location definition and implementation in the software Inspection tasks created in Inspection Management, and management of information coming from field inspections Execution of the RBI inspection plan by Stork “boots on the ground” including all prior supporting activities necessary to perform inspections on a safe & efficient way: Work preparation, planning & execution, etc. The scope also included Structures and lifting equipment inspection strategy definition. Although this is not usually part of an RBI implementation, it was added to the scope based on client’s requirement The projected included more than 3000 pipes and 600 major equipment. Through this initiative, we were able to support Freeport LNG to provide evidence to DoT in Washington in order to being able to extent government required inspection intervals from 1 to 5 years. So you can imagine the huge benefits the client had because of this. The client recognized the hard work, dedication and contribution from Stork, GE Digital and other companies involved in the project.
- Regarding our project in Turkey, In middle 2018, we started together with Socar and GE Digital an Asset Performance Management implementation project in Socar’s greenfield refinery and brownfield petrochemical unit in Aliaga. This project is special to me, not only because I was the one leading Stork services regarding mechanical integrity, but also because I had the chance to work with high experienced and knowledgeable corrosion, RBI and inspection engineers from the client, that were totally engage with the project. The challenge was to implement the same way of working and best practice in both, a greenfield and a brown field plant. There was an unforeseen extra challenge that we had to sort: COVID. It had a direct effect on the way we were implementing the project, but gladly together with the client we were able to adapt and keep on working without any critical delay.
- As I said before, the scope of the project was a full APM implementation. Apart from Mechanical integrity, other methodologies related with reliability and safety were also included, like RCM, FMEA, RCA, SIL/SIS, LOPA, Hazop and other. But specifically for Mechanical Integrity, the scope included: Risk Based Inspection analysis using RBI Criticality tool aligned with API 580, and full quantitative API 581 models Implementation of Inspection Management tool, which included the creation of inspection tasks and inspection checklists Definition of Thickness Monitoring locations and creation in the software. This is actually an ongoing task performed by the client. Implementation of Integrity Operating Windows using Asset Health Management tool and policy designer. GE Digital APM was easily connected to the process historian and the process data was accessible directly from the APM software. The policies designed by the client helped to create alarms in order to inform the integrity team when the parameters exceed the limits. The project included the implementation on a Greenfield refinery of 214.000 bbl/day and a pilot plant on the petrochemical unit. The client is currently finalizing the implementation on the refinery and performing the roll out on the petrochemical site. Through this initiative, the client was able to adjust government required inspection. Intervals were extended from 1 to 5 years and the inspection scope was defined based on the RBI recommendations, which helps to focus resources on high critical equipment, and assign appropriate strategies to the less critical. The client recognized the value of Stork and GE Digital support, to build a solid foundation for an Asset Performance Management system
- The two examples I just described are clear business cases for the client and demonstrate the value added by an Asset Performance Management System implementation, specifically related to Mechanical Integrity. On the other hand, we need to be clear that RBI is not a tool designed to extend inspection intervals, but a methodology that aims to design value added inspection strategies on critical equipment, and appropriate scope for less critical ones.
- But, how is it possible to design this cost effective inspections? It is based on an investment of time and resources that is proof to be worth it. There are different benefits from the output on each stage of an implementation like the ones we just described. In both cases the approach was similar and it is shown in this slide, that you will find is aligned with API 580 concepts and also European standard EN 16991. (click) One of the first stages is to collect the data related to mechanical integrity. Through this stage, we are able to understand, gather and organize all available data related to mechanical integrity. The level of uncertainty decreases and we have a better understanding of what is available, and also, what is missing. This is the right moment to organize and centralize the information so we have a better control. (click) The corrosion loop analysis is a crucial step. It helps to group our assets based on the susceptibility to same damage mechanisms. Through this analysis, we are able to identify the potential damage mechanisms, the degradation modes and to define the hot spots. Based on this, we are able to define the most appropriate Non Destructive Testing and to identify which are the places where we can expect more severe conditions. (click) The Risk analysis will help us to identify high critical equipment where we have to focus our resources. Following Pareto distribution, we can expect this to be a small percent of the total asset (click) Based on our corrosion analysis and risk assessment, we can define the most appropriate inspection strategies for each case. (click) We can also define alternative mitigation actions, such as Integrity Operating Windows. In this case, it will help us to mitigate the probability of failure as we have a better understanding and control of those critical parameters that could have a direct effect on our plant integrity. Using a tool like GE Digital APM will help us to optimize this process, as we can centralize in one solution the process data, the risk analysis and the inspection management system. (click) Last but not least, keeping the system updated after implementing the inspections or other mitigation actions it’s a crucial step to harvest the long term benefits we are expecting from a mechanical integrity system. GE Digital APM software helps to optimize this process through the usage of dataloaders, direct connection with the UT devices and tools that help us to perform bulk analysis. Don’t forget, although a baseline implementation can be the most time consuming stage, it does not end there. We have to encourage the people to keep feeding the system. In both case, the strategy that we applied, supported by a software like GE Digital, is helping to achieve a sustainable implementation.
- So which are the task that will help us to achieve this? This slide shows the different tactics and activities we applied during the project, in order to achieve this objectives. First, keep the management involved. If we don’t do this, then most probably the people that we need in the project won’t be involved as well. We try to keep the management involved by sharing a weekly report and having weekly meetings to discuss progress and challenges. We also work on preparing business cases to show the early wins from the project. Second, plan in advance and define resources, roles and responsibilities. One of the most common challenges in this project is to have the resources available, and to define clear roles and responsibilities. We mitigate this risk through the development of the Project Initiation Document, the project Gantt and also the weekly report. Third, define clear and simple process guides, that are adapted to the client context. To do this, we created process guides aligned with GE Digital APM Software, and performed trainings based on this documents. This documents were discussed with the client. One remark here, the process guides should be life document owned by the client. They should be reviewed to assure the current way of working is aligned with the best practice. Forth, search and communicate quick wins and business cases in order to keep the interest of the people involved in the project. We need them to understand the benefits of the effort they are investing. During this project we prepared business cases together with the client, and we share articles and white papers on different platforms. Fifth, perform trainings and train the trainer. We performed several trainings, and we also encourage the client to facilitate part of the training as well. At some point of the project, the trainings were performed together and not only by Stork or GE, but with the client as well. Sixth, use technology to support the system. GE Digital APM software is a key factor on a sustainable implementation. It helps to standardize the way of working while optimizing the baseline implementation and evergreening process. On the other hand, GE digital solution can support full APM implementations like the project in SOCAR. Seventh, empower the end user and make them own the system. The client is the owner of the system, they are the ones that will get the benefit from the implementation and this will happen if they keep the system updated. We achieved this by encouraging the client to present their colleagues best practices, application examples and business cases. We also encourage to validate all the analysis through RBI workshops. Eighth: define mechanical integrity champions. Actually, in case of Socar, it was not only about Mechanical Integrity, but also the other pillars of Asset Performance Management. They are the ambassadors of the system and will encourage other colleagues to maintain it and prepare new champions.
- The two examples I just described are clear business cases for the client and demonstrate the value added by an Asset Performance Management System implementation, specifically related to Mechanical Integrity. On the other hand, we need to be clear that RBI is not a tool designed to extend inspection intervals, but a methodology that aims to design value added inspection strategies on critical equipment, and appropriate scope for less critical ones.