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Velosi Pakistan

Development of Complete Asset Integrity & HSE Program at EPC Project Stage


Location:
Malaysia
Client:
Kebabangan Petroleum Operating Company Sdn. Bhd. (KPOC)
Region:
Asia
Services:
Complete Asset Integrity & HSE Program
OBJECTIVE

The objective was to develop complete Asset Integrity and HSE Program for KPOC facilities at EPC project stage, to aid them for smooth operation.

Further, the intent was to ensure facilities integrity and reliability, preventing any undesirable HSE impact resulting from the loss of containment and function failure.

It was also desired to them meet legislative, PPGUA Section 11 Guidelines for Inspection & Maintenance, COMPANY’s Operation Philosophy & COMPANY’s HSE Management System requirements.

Scope of Work and Deliverables

CTR-001A & CTR-001B Pipeline RBI Study-CRUDE & GAS
  • Scope of Work
    To conduct the Risk Based Inspection Study for 14” Oil & 24” Gas Pipeline
  • Assets Covered
    • 14" Oil Pipeline (132 km).
    • 24” Gas Condensate Pipeline (132 km).
  • Deliverables
    • Risk based inspection methodology for offshore pipelines
    • Mechanical Assessment Sheet
    • Pipeline corrosion and inspection strategy document
    • Inspection Reference plan (IRP)
    • RBI main technical report
CTR-002A & CTR-002B RBI Study for Jacket and SubSea Structure
  • Scope of Work
    To conduct the Risk Based Inspection Study for Top side & Subsea Structure.
  • Assets Covered
    • Topside Integrated Deck.
    • Jacket (8-Legged Spilt Jacket).
  • Deliverables
    • Substructure & top side structure tag marking methodology
    • Risk based inspection methodology for offshore structure
    • Topside and Sub-Structure Asset Register
    • Marked GA Drawings
    • RBI technical report for integrity assessment of Topside & Substructure
CTR-003A Preparation of Asset register & FMECA based RCM Analysis including PMR Development
  • Scope of Work
    To conduct the Risk Based Inspection Study for Topside & Subsea Structure.
    • Preparation of Asset Register.
    • Conduct complete FMECA based RCM Analysis.
    • Development of PMRs.
    • Validation and review of existing RCM report of critical assets.
  • Assets Covered
    • Total Tag Count = 15,000.
  • Deliverables
    • Asset register
    • FMECA Workspace
    • Preventive maintenance routines
    • RCM analysis report
CTR-003B Preparation of Bill of Material (BOM)
  • Scope of Work
    Develop the Bill of material against the mechanical rotary equipment.
  • Assets Covered
    • Total Object Type = 450.
    • Total BOM = 2000.
  • Deliverables
    • Maintenance Bill of Material
CTR-003C Preparation of Job Plans
  • Scope of Work
    • Assess and/or develop equipment hierarchy
    • Selection of equipment for developing job plans.
    • Review and collect equipment nameplate and configuration information.
    • Collection of relevant Engineering data.
    • Develop the Bill of material against the mechanical rotary equipment.
  • Assets Covered
    • Total Object Type = 450.
    • Total BOM = 2000.
  • Deliverables
    • Maintenance Bill of Material
CTR-004 Review and Updating the Risk Based Inspection (RBI) Report and Data Uploading into Meridium Software for Static Equipment, Piping Systems and Pressure Relief Devices
  • Scope of Work
    To perform and RBI assessment. Including Preparation of Asset Register, Corrosion Loops, Risk Ranking, Detail RBI Report and Corrosion & Inspection Manual.
  • Assets Covered

    The review and updating of RBI report for the following assets:

    • All Static equipment (pressure vessels, heat exchangers, etc); approx. 300 tags.
    • Piping System; approx. 4000 tags.
    • Pressure Safety Valves/Pressure Relief Devices; approx. 200 tags.
  • Deliverables
    • Asset Register
    • RBI methodology for topside static equipment, piping system and PRD
    • Corrosion loop marked up drawings
    • Static equipment and piping system corrosion and inspection manual
    • Inspection reference plan for static equipment & piping system and PRDs
    • Risk based inspection report for static equipment and piping system and PRDs
    • Data uploading into Meridium software
CTR-005 DEADLEGS,CUI,CHEMICAL INJECTION,SMALL BORE AND EROSION MONITORING POINT AND PIPING SUPPORT IDENTIFICATION RISK RANKING, AND MANAGEMENT SYSTEM.
  • Scope of Work
    These services shall include
    • Marked P&IDs and Isometric Drawings.
    • Preparation of Registers.
    • Identify the Risk Rating/ Criticality for each of the Corrosion Loop.
    • Detailed report.
    • To review and validate the RBI analysis results using Meridium.
  • Assets Covered
    • Deadlegs (inclusive of all no-flowing lines, Drains, By-Pass Lines, instrument piping, RV lines etc.)
    • CUI/PFP including WHRU (Inlet and outlet Gas Ducts) and Gas Turbine exhaust ducts.
    • Chemical Injection and Mix Point Injection Points.
    • Small Bore Piping/Flow Induced Vibration (FIV).
    • Erosion Monitoring Points.
  • Deliverables
    • Corrosion monitoring focus areas identification procedure
    • Corrosion monitoring focus areas identification report
    • Marking of Corrosion Monitoring Locations on P&IDs
    • Marking of Corrosion Monitoring Locations on Isometric Drawings
    • Corrosion Monitoring Locations Registers
CTR-006A & CTR-006B Preparation of Inspection Drawing for Topside & subsea structure
  • Scope of Work
    Preparation of Inspection Drawings for Topside & subsea structure.
  • Assets Covered
    • Topside Integrated Deck.
    • Jacket (8-Legged Spilt Jacket).
  • Deliverables
    • Inspection Drawings
    • Inspection work pack report for integrity
CTR-006C Preparation of Inspection Drawing for Topside Equipment and Piping System
  • Scope of Work
    Preparation of Inspection Drawings for Topside Equipment & Piping System.
  • Assets Covered
    • All Static equipment (pressure vessels, heat exchangers, etc); approx. 300 tags.
    • Piping System; approx. 4000 tags.
  • Deliverables
    • CML/TML Marking Methodology for Static Equipment and Piping System
    • Inspection Drawings
CTR-006D Preparation of Inspection Drawing for pipelines & Risers
  • Scope of Work
    Preparation of Inspection Drawings for Pipelines & Risers.
  • Assets Covered
    • 14" Oil Pipeline (132km).
    • 24” Gas Condensate Pipeline (132 km).
  • Deliverables
    • Inspection Drawing
    • Inspection work pack report
CTR-007 Safety Integrity Level (SIL) Study, Review & Assessment & Interval Calculation for Functional Testing
  • Scope of Work
    Velosi SIL Study scope of work is specified but limited to following:
    • Prepare Master Plan.
    • Carryout SIL Review.
    • Review of existing process HAZARD IDENTIFICATION (HAZID).
    • SIL Verification and Analysis.
    • Develop Testing Interval.
    • Generate Report and Recommendations
  • Assets Covered
    Safety Instrumentation Function = 241. (Identified from P&IDs & Cause and Effect Charts).
  • Deliverables
    • SIL Methodology
    • HAZOP Review Report
    • SIL Classification Report
    • SIL Verification report
    • Final SIL Study Report including Test Intervals
CTR-008 Review and Validation of Safety Critical Element (SCE) and Business Critical Element (BCE) & Development of Assurance and Verification Standards for SCE/BCE
  • Scope of Work
    • Review and Validation of Safety Critical Element (SCE) & Business Critical Element (BCE).
    • Development of Assurance and Verification Standards for SCE/BCE.
    • To review/validate KPOC HSE Case.
    • To review and update SCE/BCE Management Manual including managing Deviation.
    • To review/update the Procedure for Compliance Window for PM and CM in SAP.
  • Assets Covered
    Total Performance Standards = 27
  • Deliverables
    • GAP analysis Report
    • List of SCE & BCE
    • Facilities Performance Standard and Verification Scheme Prevention
    • Facilities Performance Standard and Verification Scheme Detection
    • Facilities Performance Standard and Verification Scheme Control
    • Facilities Performance Standard and Verification Scheme Mitigation
    • Facilities Performance Standard and Verification Scheme Emergency Response
    • Update Procedure for Compliance Window for PM and CM in SAP
    • Population of Data in KPOC CMMS System
CTR-009 Preparation of AIMS System Framework and Associated Documentation
  • Scope of Work
CTR-011 Preparation of Pipeline Operating Manuals for two 132 Km pipelines each (One Gas and One Oil)
  • Scope of Work
    To prepare Operation manual for the two (02) no. of pipelines which are installed from the Kebabangan (KBB) platform to Sabah Oil and Gas Terminal (SOGT):
    • 14” Φ, 132 Km long, Oil Transportation Pipeline installed from KBB Platform to SOGT.
    • 24” Φ, 132 km long, Gas Condensate Transportation Pipeline installed from KBB Platform to SOGT.
  • Deliverables
    • 14” KBB Oil Export Pipeline Operating Manual
    • 24" KBB GAS CONDENSATE EXPORT PIPELINE OPERATING MANUAL
CTR-012 Preparation of Inspection Standard Operating Procedures (SOPs)
  • Scope of Work
    Preparation of 74 Inspection Standard Operating Procedures (SOPs).
CTR-013 Preparation of Maintenance Standard Operating Procedures (SOPs)
  • Scope of Work
    Preparation of 63 Maintenance Standard Operating Procedures (SOPs)
CTR-020A & 20B Spare Parts Optimization
  • Scope of Work
    Following are the core activities carried out in this regard:
    • Verification of Critical equipment rating.
    • Identification, Classification and 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 requirements.
    • Recommendations for MIN/MAX levels for spares, Re-Order points and Economic Order Quantity(EOQ).
    • Assessment of slow & fast moving stock at reorder point.
    • Identification of excessive stock levels & subsequent elimination of un-necessary spares, leading to lower operating costs & release of tied-up capital.
  • Deliverables
    • SPARE PARTS MANAGEMENT & OPTIMIZATION PROCEDURE
    • SPARE PARTS CATEGORIZATION SHEET
    • SPARE PARTS CRITICALITY ASSESSMENT SHEET
    • OPTIMIZED SPARE PARTS LIST
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