Asset Integrity Management
Content
Asset Integrity Management – More Than Just a Fixed Equipment Inspection Program?
Joey Poret Reliability & Integrity Supervisor Chuandongbei Gas Project
© 2010 Chevron
Joey Poret
• Currently the Reliability & Integrity Supervisor for the Chuandongbei Gas Project in Sichuan, China • Over 15 years experience in Nondestructive Testing and Inspection • Over 10 years experience in the development of Risk Based Inspection and Mechanical Integrity Programs • Certified API 510 and 570 Inspector. Also holds ASNT Level III certification • Co-developer of the Chevron Upstream Asset Integrity Management process
© 2010 Chevron
Agenda
Process Safety and Asset Integrity Management Initial Asset Integrity Management Development Asset Integrity Management Process within Chevron Global Upstream Questions?
© 2010 Chevron
In the beginning, everyone had an opinion…
• Asset Integrity Management is a fixed equipment inspection program…. • will apply to all equipment… • Asset Integrity Management is a risk-based process for determining priorities of tasks… • Asset Integrity Management will double my maintenance & inspection workload…. • Integrity is the same thing as Reliability…
© 2010 Chevron
Setting the Stage
Process Safety and Asset Integrity
Guidelines for
Risk Based Process Safety
CCPS
Condition Monitoring
Inspection
Mitigation
Asset Integrity Management
Proper Functioning Equipment
© 2010 Chevron
Implementation of AIM
Global Upstream & Gas
Corporate Reliability Expectations
Supplemental Asset Integrity Requirements
Corporate Asset Integrity Requirements
AI Corporate Standard
AI Corporate Guidelines AI Gap Assessment
CGUG Implementation
CGUG Implementation
SERIP AIM Procedure
SERIP Asset Integrity Subprocess Equipment Specific Requirements Audit Protocol
© 2010 Chevron
What is Asset Integrity & Asset Integrity Management?
Asset Integrity
– The ability of an asset to perform its planned function effectively and efficiently for its intended application throughout its service life.
Asset Integrity Management builds on existing Reliability & Integrity Efforts
– Focused on high consequence areas - consequences of failure are unacceptable. – Applies a layer of rigor and governance to ensure the integrity program is being executed as planned and that variations are appropriately resolved.
7
© 2010 Chevron
Focus on Layers of Protection
Not just the Fixed Equipment
8
© 2010 Chevron
Setting the Appropriate Scope
Critical Structures Machinery
Safety Systems
Fixed Equipment
Electrical , Instrumentation and Controls
Floating Systems and Subsea
© 2010 Chevron
Asset Integrity Management Process
4 Basic Steps
Identification of Important Assets Develop Inspection, Test, and Maintenance Plans
High Consequence
Use Industry practices
Execute Inspection, Test, and Maintenance Plans
Execute the Plan
Monitoring and Managing Deviations
Right information, right person, right decision
© 2010 Chevron
Identifying “Critical” Assets/Equipment
What does “Critical” really mean?
High Likelihood Likelihood
High Risk
Low Risk
High Consequence
Consequence
© 2010 Chevron
Criticality Assessment
Integrity Hazards Examples
• Hydrocarbon Gas
Determine Top Event
• Riser Rupture and spill
Assessment Process
Determine Causes
• Corrosion
Determine Consequences
• Health, Safety, Environment, and Asset
High Consequence?
Identify Safeguards
• Emergency Shutdown Valve, Evacuation Alarm, Inspection Program
Yes
© 2010 Chevron
Develop Integrity Plans
An AIM Inspection, Test, and Preventive Maintenance (ITPM) Template is a documented reliability and integrity strategy for a particular equipment type. The ITPM plans include the scope, failure modes, recommended ITPM tasks, and a task selection matrix. Templates feed into local RBI / RCM / and FMEA reliability processes based on local considerations
© 2010 Chevron
Variation Management Nonconformances
Focus on Variation Management Levels of Governance
Nonconformances
Discrepant Material Condition - affects the ability to perform integrity critical functions Overdue Integrity Tasks – a task is planned to exceed the required completion date.
Levels of Governance Levels of Governance
Variations must be addressed with the appropriate level of management involvement.
14
© 2010 Chevron
Manage Nonconformances
“The right people, make the right decision, based on the right information”
© 2010 Chevron
Do you still have the same opinion?
• AIM program is a fixed equipment inspection program…. • Asset Integrity Management will apply to all equipment… • Asset Integrity Management is a risk-based process for determining priorities of tasks… • AIM program will double my maintenance & inspection workload…. • Integrity is the same thing as Reliability…
© 2010 Chevron
Questions???
© 2010 Chevron
Joey Poret Reliability & Integrity Supervisor Chuandongbei Gas Project
© 2010 Chevron
Joey Poret
• Currently the Reliability & Integrity Supervisor for the Chuandongbei Gas Project in Sichuan, China • Over 15 years experience in Nondestructive Testing and Inspection • Over 10 years experience in the development of Risk Based Inspection and Mechanical Integrity Programs • Certified API 510 and 570 Inspector. Also holds ASNT Level III certification • Co-developer of the Chevron Upstream Asset Integrity Management process
© 2010 Chevron
Agenda
Process Safety and Asset Integrity Management Initial Asset Integrity Management Development Asset Integrity Management Process within Chevron Global Upstream Questions?
© 2010 Chevron
In the beginning, everyone had an opinion…
• Asset Integrity Management is a fixed equipment inspection program…. • will apply to all equipment… • Asset Integrity Management is a risk-based process for determining priorities of tasks… • Asset Integrity Management will double my maintenance & inspection workload…. • Integrity is the same thing as Reliability…
© 2010 Chevron
Setting the Stage
Process Safety and Asset Integrity
Guidelines for
Risk Based Process Safety
CCPS
Condition Monitoring
Inspection
Mitigation
Asset Integrity Management
Proper Functioning Equipment
© 2010 Chevron
Implementation of AIM
Global Upstream & Gas
Corporate Reliability Expectations
Supplemental Asset Integrity Requirements
Corporate Asset Integrity Requirements
AI Corporate Standard
AI Corporate Guidelines AI Gap Assessment
CGUG Implementation
CGUG Implementation
SERIP AIM Procedure
SERIP Asset Integrity Subprocess Equipment Specific Requirements Audit Protocol
© 2010 Chevron
What is Asset Integrity & Asset Integrity Management?
Asset Integrity
– The ability of an asset to perform its planned function effectively and efficiently for its intended application throughout its service life.
Asset Integrity Management builds on existing Reliability & Integrity Efforts
– Focused on high consequence areas - consequences of failure are unacceptable. – Applies a layer of rigor and governance to ensure the integrity program is being executed as planned and that variations are appropriately resolved.
7
© 2010 Chevron
Focus on Layers of Protection
Not just the Fixed Equipment
8
© 2010 Chevron
Setting the Appropriate Scope
Critical Structures Machinery
Safety Systems
Fixed Equipment
Electrical , Instrumentation and Controls
Floating Systems and Subsea
© 2010 Chevron
Asset Integrity Management Process
4 Basic Steps
Identification of Important Assets Develop Inspection, Test, and Maintenance Plans
High Consequence
Use Industry practices
Execute Inspection, Test, and Maintenance Plans
Execute the Plan
Monitoring and Managing Deviations
Right information, right person, right decision
© 2010 Chevron
Identifying “Critical” Assets/Equipment
What does “Critical” really mean?
High Likelihood Likelihood
High Risk
Low Risk
High Consequence
Consequence
© 2010 Chevron
Criticality Assessment
Integrity Hazards Examples
• Hydrocarbon Gas
Determine Top Event
• Riser Rupture and spill
Assessment Process
Determine Causes
• Corrosion
Determine Consequences
• Health, Safety, Environment, and Asset
High Consequence?
Identify Safeguards
• Emergency Shutdown Valve, Evacuation Alarm, Inspection Program
Yes
© 2010 Chevron
Develop Integrity Plans
An AIM Inspection, Test, and Preventive Maintenance (ITPM) Template is a documented reliability and integrity strategy for a particular equipment type. The ITPM plans include the scope, failure modes, recommended ITPM tasks, and a task selection matrix. Templates feed into local RBI / RCM / and FMEA reliability processes based on local considerations
© 2010 Chevron
Variation Management Nonconformances
Focus on Variation Management Levels of Governance
Nonconformances
Discrepant Material Condition - affects the ability to perform integrity critical functions Overdue Integrity Tasks – a task is planned to exceed the required completion date.
Levels of Governance Levels of Governance
Variations must be addressed with the appropriate level of management involvement.
14
© 2010 Chevron
Manage Nonconformances
“The right people, make the right decision, based on the right information”
© 2010 Chevron
Do you still have the same opinion?
• AIM program is a fixed equipment inspection program…. • Asset Integrity Management will apply to all equipment… • Asset Integrity Management is a risk-based process for determining priorities of tasks… • AIM program will double my maintenance & inspection workload…. • Integrity is the same thing as Reliability…
© 2010 Chevron
Questions???
© 2010 Chevron
