Valve Integrity Management System (VIMS) Development for Petrochina International Jabung

Transcription

1 Managing Risk for Better Life Valve Integrity Management System (VIMS) Development for Petrochina International Jabung Dr. Budi L Hakim, MT Valve Risk and Integrity Specialist PT.WAHYU CIPTA MANDIRI Jabung, December 20, 2016.

2 Table of Contents 1. Introduction and Background 2. VIMS and Integrity Cycle 3. Scope and Coverage 4. Inspection Results 5. VIMS and Results Risk Assessement 6. Conclusions and Recommendations

3 Part I Introduction

4 1. Introduction 1.1. Introduction & Background PETROCHINA INTERNATIONAL JABUNG, LTD., as a production-sharing contractor of SKKMIGAS and as the operator of the Jabung Block, Jambi Province, Sumatra, Indonesia. They have much of valve on pipeline & piping system, consit of valve function and type : Shut Down Valve (SDV) Ball Valve (BV) Blow down valve (BDV) Control valve (CV) Choke valve (CHO) Check Valve (CHV) Gate Valve (GV) The Valves above will be develop to Valve Integrity Management Systems (VIMS). VIMS is a comprehensive process that covers all phases of the evaluation cycle start design integrity until operation by applying the most appropriate strategy of testing, inspection, integrity assessment, maintenance and repair, so that the risk of valve can be managed to a level that is acceptable to develop techniques and methods detection, prevention and effective risk mitigation.

5 1. Introduction The Valve Integrity Management System will help to know : How safe is our valve? What is the valve condition today? Future? How do we manage it to ensure its reliability? Can the valve operated under current condition? Can the valve operated for future condition? How we convince the stake holder on valve safety? PETROCHINA INTERNATIONAL JABUNG LTD. Concern to perform Valve Integrity Management System (VIMS) Development. These services proposed to preventive action for Valve Risk and Integrity Assessment on Specific Valve Section, Inspection, Maintenance and Repair Strategy to anticipate valve degradation (corroded, passing and leaking) which will be affecting or disturbing to the oil and gas production operation.

6 1.2. Objectives 1. Introduction The objective of the study is: Independent valve integrity assessment including failure cause review Savings on man hours Significant savings on lost revenue from unplanned SD Live monitoring and failure mode feed Quality control and assurance on valves Reduction in the occurrence of serious incidents Continuous valve integrity monitoring 1.3. Volume of Work The Volume of work valve Integrity management system (VIMS) Development are coverall valve on the pipeline/flowline in jabung, North geragai field include station and makmur field Tanjung Timur, Jambi. This integrity status cover : Shut Down Valve (SDV), Ball Valve (BV), Blow down valve (BDV), Control valve (CV), Choke valve (CHO), Check Valve (CHV), Gate Valve (GV)

7 1. Introduction 1.4. Scope of Work. Job Requirement All inspection will conducted by the Contractor/Consultant, PT as report in appendix A Summary of Valve Integrity and Inspection Status Inspection done by visual inspection, dimensional, infrared thermography imager and function (turn) test in some cases (operation status depending) Passing test was not included in inspection, due to inability to close operating valves which will interrupt the production Visual condition deemed able to represent fitness of valves, and this based on conservative judgments Detailed descriptions of findings available in appendix B. Master Data of Valve Integrity Level of detail of inspection and recommendation is for appraise stage To allow project to develop options, risk and priority are provided to lead scope definition Small valves < 1 1/2 are exclude from this scope, and 1 1/2 deemed as 2 valves Matrix is made with assumption that deep inspection is not desired (time availability, shutdown interrupts, etc). So replacement does not always mean valve is not repairable. Replacement means insitu repair is impossible.

8 1.5. References 1. Introduction 1. Pipeline Design Pressure and Temperature, Petrochina International Jabung, Doc. No. BCD RPT , 16 th June Design Criteria for Onshore Pipeline, Petrochina International Jabung, Doc. No. BCD CRT , 7 th March ASME B16.10 Face-to-face and end-to-end dimensions of ferrous valves. 4. ASME B16.5 Face-to-face and end-to-end dimensions of ferrous valves. 5. ASME B16.34 Steel valves, flanged and butt-welding end. 6. ASME B 31.4, Liquid Petroleum Transportation Piping System (2010) 7. ASME B 31.8S, Managing Integrity of Gas Pipeline (2010). 8. ASME B 31.8, Gas Transmission and Distribution Piping System. 9. Muhlbauer, Pipeline Risk Management Manual, 3 rd Edition, GPP (2004). 10. API 581, Risk Based Inspection, Resources Document 11. API 1160, Managing Risk of Hazardous Liquid Pipeline (2010).

9 1.5 References 1. Introduction 12. API 1160, Managing Risk of Hazardous Liquid Pipeline (2010). 13. NACE SP 0106 (2006), Control of Internal Corrosion in Steel Pipelines and Piping Systems. 14. MSS SP-25 Standard marking system for valves, fittings, flanges, and unions. 15. MSS SP-54 Quality standard for steel castings for valves, flanges and fittings, and other piping components radiographic examination method. 16. MSS SP-55 Quality standard for steel castings for valves, flanges and fittings, and other piping components visual method for evaluation of surface irregularities. 17. API Std 598 Valve inspection and test. 18. API Spec 6D Pipeline valves (gate, plug, ball and check valves). 19. API Std 603 Corrosion-resistant, bolted bonnet gate valves. 20. API Std 600 Bolted bonnet steel gate valves for petroleum and natural gas industries. 21. API Std 602 Compact carbon steel gate valves. 22. API Spec 6D Specification for pipeline valves, end closures, connectors and swivels

10 1.6. Valve Basic Design Valve definition A valve is a mechanical device that controls the flow of fluid and pressure within a system or process. A valve controls system or process fluid flow and pressure by performing any of the following functions: 1. Stopping and starting fluid flow 2. Varying (throttling) the amount of fluid flow 3. Controlling the direction of fluid flow 4. Regulating downstream system or process pressure 5. Relieving component or piping over pressure

11 Valve Basic Design Basic Design Valves Type : 1. Ball 2. Gate 3. Globe 4. Check 5. Butterfly 6. Plug 7. Relief and safety valve 8. Etc Valve Integrity Management (VIM) is the cradle to grave approach of understanding and operating valve in a safe, reliable manner. VIM programs are systems managed by valve owner-operators that consider all stages of the valve life cycle, from conception, to engineering and design, construction, operation, inspection, and finally to repair/replacement when necessary

12 Part II VIMS and Integrity Cycle

13 CORRCETIVE ACTION & REPAIR 2. VIMS and Integrity Life Cycle POLICY & STRATEGY DESIGN AND CONSTRUCTION RISK ASSESSMENT & PROGRAM PLAN VIMS DATA MANAGEMENT PROGRAM EXECUTION PERFORMANCE MEASUREMENT & RISK ASSESSMENT ABANDON AND DECOMMISIONING Figure 1. VIMS and Integrity Life Cycle

14 Part III Collect data & Inspection Result

15 Collect data & Inspection Result 3.1 Maping Area VIMS by GPS Figure 2. Maping area VIMS with GPS recording coordinate of all point of valve

16 3.2 Isometric Drawing VIMS Coverage Figure 3. Isometric Drawing VIMS Coverage

17 3.3 Service Parameters Sources: Ref No 1, 2, 7 and as PetroChina As-built drawing

18 Product Composition (as per June 2015) Sources: 321/NGF-Lab/03/June/2015 Analysis Result Composition of Hydrocarbon Liquid, Field Engineering Laboratory PetroChina International Jabung 2113/NGF-Lab/02/June/2015 NGF Daily Report, Jabung Laboratory PetroChina International Jabung

19 Part IV Valve Inspection Results (VC by GPS, VLI, VIR, IRT)

20 4.1. Valve Coordinat Inspection Figure 4. Valve Coordinat Inspection by GPS

21 4.2 Visual Location Inspection : Figure 5. Visual Location inspection

22 4.3 Valve Inspection Result : Point of Interest Figure 6. The Valve with tag no BV-070C-BGP was badly corroded on body and need to repair coaing /repainting

23 4.3 Valve Inspection Result : Point of Interest Figure 7. The Valve with tag no above was leaking on the grease fitting

24 Figure 8. the Valve wiit tag no above was leaking on gear box ( gear operator) 4.3 Valve Inspection Result : Point of Interest

25 4.3 Valve Inspection Result : Point of Interest Figure 9. the Valve wiit tag no above was leaking on gear box ( gear operator)

26 4.4 Infrared Thermography Inspection Result : Point of Interest Figure 10. the Valve wiit tag no above indicated leaking on grease fitting

27 Figure 11. the Valve wiith tag no above indicated leaking on gear box ( gear operator) 4.4 Infrared Thermography Inspection Result : Point of Interest

28 Part V VIMS and Risk Assesment

29 Results of Risk Assessment The objective of the risk study is: 1. To develop a risk assessment methodology applicable to onshore and offshore Valve. 2. To perform risk assessment qualitatively associated with possible hazard for all Valve and to evaluate the risk profile along the line. 3. To prioritize inspection plan and schedule according to the risk results. 4. To assign effective inspection measures to detect any hazards and their effect of the integrity of the pipeline. 5. To set up the maintenance and repair strategy regarding the risk results. Managing risk is managing the uncertainty to increase the confident level to operate Valve

30 Goal of Risk Assessment through Integrity Management The ultimate goal of risk assessment is to identify the highest risk of valve so that operators can develop methods and planning of detection, prevention and effective mitigation based on priorities in accordance with the risk rating obtained (ASME B31.8S and API 1160). From the standpoint of integrity, risk mitigation is done by lowering PoF through the best inspection, maintenance and repair (IMR) strategy. Therefore, it is important to identify the largest contributors to PoF of segment / section specific pipeline being evaluated. Valve IntegrityManagement Project 40

31 Valve Risk Assessment Methodology Figure 12. The Valve Risk Assessment Methodology Sources : Modified Muhlbauer s Risk Assessment Manual, ASME B31.8S, NACE SP 0106, Best Engineering Practices, and Pipeline Transmission Operation History.

32 Risk Matrix and Formulation Risk = Probability/Likelihod of Failure x Consequence of Failure Figure 13. Risk Matrix and Categorization (Ref No 6. API 581, Risk Based Inspection, Resources Document) 43 Valve IntegrityManagement Project

33 Figure 14. Chart Valve Risk category & Risk Matrix Category Valve integrity management system 43 Valve IntegrityManagement Project

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41 BV-0082-KP4 BV-003I-GMH 9 GV-0003P-GMH 19 BV-0089A-KP BV-0067-KP 22 GV-0099D-NEB #1 PAD BV-0076-KP 45 GV-0130D-KP 19 BV-0143A- NEB # 09 PAD GV NEB # 09 PAD SDV-0123-SWB PPF BV BPG SDV-0134-BGP SDV-0131-BGP BV-070C-BGP BV-0102-GMH STN GV-0102A-GMH STN BV-0111-NB STN BV-0085-NEB STN BV-0100-NEB STN BV-0096-NEB STN BV-0058A-KP 17 CHV-0047A-KP 17 BV-0062-KP BV-0042C-KP BV CECIL BRIDGE BV KP BV-0046-KP BV-0006A-MK 2 PAD BV-0012B-MK 5 PAD BV-0021B- MK 6 PAD SDV-0059-KP BV-0030A-LAUNCHER CPS GV-0140A- CPS PLANT SDV-0084C- CPS PLANT BV-0053-LAUNCHER 770-VL-102 SDV-0064C - LAUNCHER NGF BV-0037-KP PoF and CoF Score PoF and CoF Score Versus Tag No. Valve PoF CoF Tag No. Figure 15. PoF and CoF Profile versus Tag No valve

42 The Largest Contributor to Risk Valve Probability of Failure 1. Valve Types and Design Index (20%). 2. Valve Operation, Maintenance, and Inspection Index (30%) 3. Valve Internal and External Corrosion Index (40%) 4. Valve Third Party Damage Index (10%) 5. Valve Function (0-100%) Consequency of Failure 1. Business / Production Loss (40%) 2. Safety of Population (30%) 3. Cost of Asset (20%) 4. Company Reputation (10%) 5. Unsafe /Loss Production (0-100%)

43 6. Conclusions and Recommendations 6.1 Conclusions 1. Preliminary VIMS has been done for Petrochina covering by list valve from volume of work. 2. Maping area VIMS from list valve from volume of workdata and actual update for collect data & inspected of valve has been done with GPS recording coordinate of all point of valve 3. Base on visual inspection, good condition are 254 ea, finding valve corroded are 6 Ea and valve mossy n moldy are 1 Ea. 4. Base on dimensional inspection, the all valve size inspected consist of end to end & flange thickness are standard size with accordance API 6D, ASME/ANSI B and ASME/ANSI B Base on IRT inspection, indication for good condition are 252 ea, indication finding valve leaking from gease fitting 3 Ea, leaking from gear operated valve are 5 Ea and valve mossy n moldy are 1 Ea 6. There are some minor leak observed during infrared inspection at valves that need attention and repair. 7. From risk assessment study, it was observed that form all valve population inspected of 261 Ea that in very low risk category are 19 Ea, low risk category are 228 Ea, medium risk category are 1 Ea and high risk category 13 ea.

44 6. Conclusions and Recommendations 6.1 Conclusions 8. No very high risk category observed on the valve inspected. 9. For high risk category need to very important solve problem are 3 Ea leaking from fitting grease, leaking from gear operated valve are 5 Ea. 10.For other high risk category are 5 Ea cause by big size valve and the PoF and CoF score will increase. 11.No very high risk category valve observed. 12.Only 1-5% population valve need focus on inspection and maintenance plan

45 6. Conclusions and Recommendations 6.2 Recommendation: 1. The VIMS program & update data base valve need to be continue. 2. To the valves high risk category need attention and must be maintenance priority 3. To the valves leak from grease fitting must be closed to use leaklock fitting (temporary) and the next must be replaced if the line shutdown 4. To the valves leak from gear operator (gear box) must be closed to use sealant (temporary) or online maintenance / insitu repair and the next must be replaced if the line shutdown 5. To the valves was corroded, mossy & moldy must be maintenance priority & recoating / repainting. 6. To perform periodic maintenance (online maintenance/ greasing) for all valves including functioning test include partial or full stroke test 7. To warn third party /people in populated areas by using bilboard, warning mark and providing regular non-formal meeting to ensure people understand the fire & explosion hazards in case of pipeline leak or rupture. 8. to recoating the all the valve that subject to coating damage due to environment interaction..

46 6.3 Recommendation to Mitigate the Risk Population Valve Table. IMR strategy for risk mitigation associated with external corrosion, internal and function for population valve

47 THANK YOU