Webinar | GE & Stork | APM Best Practices - Mechanical Integrity
1. Plaatje leaflet
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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
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
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.
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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:
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A Mechanical Integrity implementation for a liquefaction plant operated by Freeport LNG in Texas, USA
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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.
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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.
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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.
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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
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Based on our corrosion analysis and risk assessment, we can define the most appropriate inspection strategies for each case.
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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.
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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.