Integrity Management of Brownfield Projects:

Challenges and Rewards

Presenters

Monzar Najami Hooman Takhtechian

Principal Inspection Principal Corrosion

Engineer Engineer

1 Asset Integrity
 Integrity Management of Brownfield Projects: Challenges and Rewards

Agenda

• Introductions
• About Oceaneering
• Integrity Build : Definition and Objectives
• Brownfield RBA Overview
• Challenges of RBA Programmes
• Operational Elements and Influencing Factors
• Industry Best Practice - Process, Plant, People, Performance
• Conclusion and Discussion

2 Asset Integrity
 About Oceaneering
Oceaneering provides services to deep water, space, Oil & Gas, and
Motion entertainment environments to execute with new, leading-edge
connections to solve tomorrow’s challenges, today.
Founded in 1964 as an ROV/ Diving specialist
Oceaneering Acquisition of OIS in 2004 ( Asset Integrity )
Branches in 5 continents
Has more than 8000 employees

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 Worldwide Locations
4
 Inspection, Maintenance,
and Repair (IMR) Asset Integrity

Video, Communications, and Grayloc® Connectors

Applications

Decommissioning
Installation Services

Diving Services

Installation Workover Umbilicals

Control Systems (IWOCS)

Subsea Connections
BOP Intervention

ROV Services

Intervention Tooling
Pipeline Repair
Subsea Control
Valves

Dredging
Flow Assurance
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 Integrity Management of Brownfield Projects: Challenges and Rewards

Asset Integrity

Risk, Reliability, and Subsea Engineering

Data Management Maintenance Engineering Solutions Solutions

Risk assessments, Solutions for corrosion, Fitness-for-service

Development,
critical analysis structural, pipeline, and engineering and
management, and
reliability studies, process plant inspection,
maintenance of
CMMS optimization, requirements including due diligence studies,
customer and
maintenance programs, asset life assessments inspection campaign
company software
systems spare parts analysis management, and
pipeline engineering

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 Integrity Management of Brownfield Projects: Challenges and Rewards

The Aim of this Presentation is to :

 Share Best Practice for Operators/EPC/Vendors for a more efficient Integrity New
Build (INB) programmes (Brownfield)

 Respond and adapt to Cost, efficiency, and Quality demands

 Lessons learnt/Best Practice in INB can benefit the existing operating facilities (e.g.
Generic RBA / FM programmes)

 The Use of Technology (Recent Software RBA, CAD, IDB -Inspection Data Base)
improves Governance & Standardization

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 Equipment Life Cycle Flowchart

Scope Definition

Design & Offsite Manufacture

Historical Data where
available e.g.
- corrosion rates

I N T E G R I T Y
Design - suitable materials

ETP 32-10
- inspection requirements

B U I L D
Asset Records

Procurement including offsite

manufacture

Site Fabrication, Construction & Testing

Site Construction
ETP 32-20

Procedures
Handover / Acceptance

Auditing
Commissioning
O P E R A T I O N

Operation

Competent
Resources
ETP 32-30 & ETP 32-40

Operation

In-Service Inspection

Training

Maintenance, Repairs & Replacements

Alterations, Re-rating & Life Extension

Decommissioning
Retirement

Dismantling, Demolition & Disposal

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 Integrity Build

Integrity Build: Why is it required?

• Compliance & Standardization (Legislative Governance, such as safety Case, & Regional
Requirements)
• Ensure that integrity is designed into the project.
• To ensure safe and reliable operation of the facilities, by producing Inspection and Integrity plans,
uploaded into the Maintenance Management System (MMS)

Integrity Build: Deliverables?

• Front End Integrity Management Strategies include RBA, PSV, Vibration, Baseline, FHA (Flexible
Hose Assembly), Inspection Dwgs, Structural, etc.
• (Desk Top related)Integrity Build RBA process, Inspection Plans, CUI register, PSV assessment
etc.
• (Site related activities): Programmes Baseline Inspection, Vibration, PSV, Dead Legs, etc.
implementation during the Facilities Construction stage prior to commissioning
• Operation Related Strategies: FIMS, CMS, FM Strategy

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Governance & Compliance Integrity Build
Project Deliverables
Operator/Partners/Region
Integrity Management Systems
Process details

Case for Safety CMMS Upload

Use of Continuous
Technology Improvement
IMS Strategies Inspection Job

Commissioning
IMS & Philosophy,
Plans ( WSE)
Implementation Risk Based Assessment
strategy Project
Close out
Vibration Inspection
and
Local Processes &
Programme Handover
Integrity Systems
PSV
Project
Baseline Inspection Vibration Lessons
Programme Learnt
Engineering Design Fabric Maintenance
Review & Revamp PSV Testing
Project Dead Leg
Programme
Stakeholder Life Cycle
Engagement Approach
Front End IMS
Corrosion
Strategies
Management

PHASE (A) PREPARE PHASE (B) DEVELOP PHASE (C & D) APPROVE DELIVER

10 Sept 2016
 A Typical RBA process (Greenfield vs. Brownfield)

Planning Implementation

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 Brownfield RBA Process Highlights

Critical path data maturity & Quality for Brownfield revamp project

Historical Data Format /content

/availability/QA /

Revamp Project Inspection Results

Inspection reports interpretation/Actions

Existing WSE Format and Contents

Fitness for Design Helpful and insightful

Assessment:

Existing MMS Comprehensive

(SAP/Maximo etc) /Redundant

Brownfield data Input

Crucial for PoF evaluation Relevant Insights

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 RBA Process for a typical Brownfield Facility
High level Criticality review as per
-Location (Offshore/Onshore)
-Unit/System criticality (Safety, Environmental, Business)
-Process/Utility
-Fluid corrosivity (Wet, Dry, Sour, ...)
-Material Selection (CS, CRA, Clad, Non-metal, ...)
-Threat complexity and barrier effectiveness
-Inspection requirements / complexity
-History of failure / Significant anomalies in the same or similar facilities

High Medium Low

•Feed gas / Unstabilized HC • Dehydrated HC, Export product • Low critical utility (Air, Nitrogen,
condensate • Utility system (Boilers, lube oil, fire water ...)
•Offshore unmanned platform • Closed drain • Low critical Vendor package
•Separation and Processing facilities (chemical injection, waste water
• Critical vendor package
•Carbon steel material for wet treatment, ...)
system • Inland
• Non metals
•No barrier: Uncoated CRA • Barrier effectiveness to be
reviewed: Storage tank CP / • Passive barrier by design
•Failure history in the same / similar
facilities. Requirement for baseline Chemical injection • No major failure in the industry
•Intrusive inspection / Advance NII • Failure history in the industry • Only visual inspection
techniques required • No complex NDT / Known
CMLs

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 Challenges in conducting a Brownfield RBA

Challenges in the consequence assessment

-Methodology (Quantitative/Qualitative)
-Stakeholders engagement
-Different scenarios
-Various modes of failure
-Availability of backup data
-On time assessment

Stakeholders Failure modes Backup data Methodology Time

• Process safety • Pin hole leak • New / old • Brainstorming • Adequate time
engineer • Medium size studies sessions before RBA
• Environmental • HAZOP, • Software assessment
• Large size
engineer • FRA, • Manual
• Full rupture
• Mechanical • ENVIID calculation
engineer • Use of other
• Operation and QRA done
Maintenance

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 Challenges in conducting a Brownfield RBA

Challenges in the data collection

-Data availability
-Data validation
-Anomaly reports
-Tagging
-Monitoring records

Data Availability Data validation Anomalies Tagging Monitoring

• Material • Traceability • List of • Corrosion circuit • Process data
certificates • Gap analysis anomalies mapping • Corrosion rate
• Welding • MOC ( • NCRs / TQs • Insp. Isometrics • Chemicals
procedures management of • Repair records CML tagging
• Deposits/
• Equipment change) • Root cause Corrosion
drawings Failure Analysis product analysis
• Datasheets • FFS ( fitness for
• Baseline data service)
• Inspection • ...
reports
• ...

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 Challenges in conducting a Brownfield RBA

Challenges in the Threat Assessment

How much credit can we take from the existing data?

Monitoring Corrosion rates

Materials Anomalies Risk assessment
records from Inspection

• Availability • Baseline data • Change in • Manufacturing • Participation of

available? material spec defects operation rep.
• Reliability and standard In the RBA
• Thickness • Root cause
• Validity due to measurement • Coating type analysis review sessions
change in the technique available? • Late life
process • Manufacturing
• Spot/Scan? process scenarios
• Sampling
locations • Measurement • Cladding/ weld-
relevant? points overlay
• ... • ...

Solution: Hybrid corrosion rate assessment

Theoretical estimated rate vs. Calculated rate based on actual data

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 Challenges in conducting a Brownfield RBA

Typical list of damage mechanisms considered in the pressure system RBA

Damage Type Internal Threats External Threats

Amine corrosion Atmospheric corrosion

Chloride pitting corrosion Chloride pitting corrosion

CO2 corrosion Corrosion under insulation / fireproofing (CUI / CUF)

Corrosion by chemicals (including well workover fluids) Crevice corrosion (including flange faces)

Crevice corrosion (including flange faces) Galvanic corrosion

Erosion, erosion-corrosion and solids-free flow-induced damage Marine corrosion (including external MIC and Splash Zone)

Galvanic corrosion Mechanical damage (abrasion, wear, galling and fretting)

Wastage
H2S (pitting) corrosion Soil corrosion (including external MIC)

High temperature degradation Stray current corrosion

Mechanical damage (abrasion, wear, galling and fretting)

Microbiologically Influenced Corrosion (MIC)

Oxygen corrosion

Preferential weld corrosion (PWC)

Stray current corrosion

Amine stress corrosion cracking Carbonate stress corrosion cracking

Chloride stress corrosion cracking (SCC) Chloride stress corrosion cracking (SCC)

Fatigue (Corrosion) Fatigue (Corrosion and Mechanical)

Cracking Hydrogen embrittlement Hydrogen embrittlement

Hydrogen induced cracking (HIC) and Stress-oriented HIC (SOHIC)

Liquid metal embrittlement (Hg)

Sulphide stress cracking (SSC)

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 Challenges in conducting a Brownfield RBA

Challenges in the Brownfield Deadleg Management

-Deadleg identification
-Deadleg risk assessment
-Operational / Physical deadlegs
-Mitigation

Deadleg Operational /
Threat assessment Mitigation in place
identification Physical deadlegs
• Isometrics • Failure histories • Change in the • Draining
available? captured? process • Flushing
• Line walk carried • Sampling from captured?
• Chemical
out? deposits / • Isolated, treatment
• Deadleg tagging stagnant fluids mothballed,
decommissioned • Preservation
(old and new philosophy
tags) items
• ... • ...

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 Challenges in conducting a Brownfield RBA

Challenges in the Brownfield CUI Management

-Coating Spec. under insulation

-Insulation type
-Removal of unnecessary insulation
-High critical location
-Failure histories

High critical Mitigation in

Coating Risk assessment
locations place
• Coating spec for • Failure histories • Cyclic • Removal of
the temperature captured? temperature unnecessary
• Old/New spec. • Insulation type • Branches insulation
• ... • Actual operating • damaged • Available
temperature cladding? screening and
NII techniques?
• ... • Line walk done?
• ...

19 Asset Integrity
 Challenge of developing and implementing an asset integrity
program during Brownfield development projects

QA issues
during
Schedule and Risk for delay in implementation
milestones often emerging vital Task conflict- Cost variance – clear and
take primacy integrity related Planning throughout the common
over integrity interventions Challenges project acceptance
management
criteria for
processes,
existing
anomalies

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 Operational Elements and Influencing Factors

OPS
ELEMENTS
I N F L U E N C E

GOVERNANCE PLANT STATUS ORGANIZATION MEASUREMENT

STANDARISATION DOCUMENTATION ENGAGEMENT COMPETENCY

BEST BEST PRACTICE BEST PRACTICE BEST PRACTICE BEST PRACTICE

PRACTICE

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 Best Practice-Process

• Clear Governance and Compliance strategies (overseas

element)
• Timely Brownfield RBA scheduling :
GOVERNANCE
• Post revamp project (Not too early and not too late )
PLANT STAUS ORGANIZATION MEASUREMENT

• Generic Inspection Plans for Low Criticality levels

• Standard Inspection isometric – same process
STANDARISATION • Semi quantitative RBA approach to equipment of same category

DOCUMENTATION ENGAGEMENT COMPETENCY

• Baseline Inspections: Define early & align with Project Plans

• Define and Engage with stakeholders early vendors /project
etc
• More scrutiny re Revamp project documentation and decision
making processes
BEST PRACTICE
• Ensure commensurate costing for Brownfield RBA
BEST PRACTICE BEST PRACTICE BEST PRACTICE
• FIMS & CMS Strategies to be developed and aligned with the
RBA process
• Document Control : Extend the change processes outside of
the organization to include Vendors ( Share documents)

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 Best Practice-Plant

• Preservation of existing equipment

• Plant specific: U/G Piping- CP- CUI- MIC-FM
• Acceptance Criteria during revamp project and repairs
PLANT STATUS • Permanently mothballed equipment/pipework
GOVERNANCE ORGANIZATION MEASUREMENT
• FM Opportunities- Blasting on Live Lines

• Historical data
• Punch List items – and handover process
• As build P & ID and construction drawings
DOCUMENTATION
• In-situ verification of existing equipment ( 3D laser mapping)
STANDARISATION ENGAGEMENT COMPETENCY

• Boundary Definition ( Pipelines/ Utilities etc)

• Define process systems ( what is included)
• Pressure Systems - limits ( e.g. Tubing- vendor skids,
auxiliaries etc)
• Interface documents -Elect/Inst/Pipeline/Vendors processes
BEST PRACTICE
• Vendor skids documentation and inclusion in baseline
BEST PRACTICE BEST PRACTICE BEST PRACTICE
• FM strategy applicable to Brown field

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 Best Practice-People

• Management Structure “Organogram”

• Roles & Responsibilities
• Outline interface processes
ORGANIZATION • Project Primacy pitfalls
GOVERNANCE PLANT STATUS MEASUREMENT

• Plant operators –Engage workforce-with local experience

• EPC/OPS/IMS/Operator – Communication protocols
• Use of Technology ( Docs sharing, comms, etc)
ENGAGEMENT
• Understand Company Culture and Human Element
• More Engagement with RBA workshops
STANDARISATION DOCUMENTATION COMPETENCY

• Stakeholder identification, engagement plan

• Establish effective communication -”Integrity Sale pitch”
• Human Factors Vs Process: Ownership, Inclusion, Work load,
error traps, latent conditions,
BEST PRACTICE
• Competency, Training and Awareness
BEST PRACTICE BEST PRACTICE BEST PRACTICE
• Safety during Brownfield Revamp- “ e.g. beware of live lines”
• Integrity TA for revamp : Operation Team

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 Best Practice-Performance

• Project KPI and periodic monitoring

• Peer Review
• Self Verification Process
MEASUREMENT • Integrity Reviews ad as built corrections
ORGANIZATION
GOVERNANCE PLANT STATUSN

• Competency Reviews ( QA system)

• Technical Reporting Validity
• Use of technology/software / data management protocols
ENGAGEMENT COMPETENCY
• Lack of experience of integrity inspection process
STANDARISATION DOCUMENTATION (construction vs. Integrity)

• Forensic Inspections: Minimize /Manage

• Improve Inspection QA/Reporting/Recommendation ( error
BEST PRACTICE traps)
BEST PRACTICE BEST PRACTICE
BEST PRACTICE • Identify and manage Critical Path risks at early stages of the
project

25 Asset Integrity
 Integrity Management of Brownfield Projects: Challenges and Rewards

Conclusion and Discussion

• RBA Brownfield Facilities; It is an Acid Test for the Facilities
• Major opportunities ( FM Blasting on Live Lines/Temp Repairs/RO)
• Generic RBA’s for low risk items( Cuts cost and adds value)
• Project primacy : Risk Review By Operator
• Get in early – Design phase- before manufacturing start
• Implementation Baseline inspection to be part of Engineering Projects
• Team work and local Ops experience inclusion
• The Need of a rigorous selection process for Integrity Contractor
• Revamp Project: Reporting and recommendation ( QA issues)

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Thank You for Your Attention!

For more information please visit:

www.oceaneering.com/asset-integrity

Or contact:
Monzar Najami ([email protected])
Hooman Takhtechian ([email protected])

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