ASSET INTEGRITY & PERFORMANCE MANAGEMENT

  • April 6, 2020 - April 17, 2020
    8:00 am - 5:00 pm

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Improving the effectiveness of asset management and integrity activities is vital to ensuring physical assets perform their required functions, operate reliably and thereby support corporate goals and objectives. A successful Asset Integrity Management Program incorporates design, maintenance inspection, process, operations and management concept; all having a direct impact on the integrity of infrastructure and equipment.

As a result, best practice facilities have implemented comprehensive, fully integrated systems and a culture directed at gaining greater lifetime effectiveness, value, safety, availability, profitability and return from production and manufacturing assets. The asset integrity management is a 10 – day training course designed to assist asset integrity managers with achieving maximum production capacity at the lowest lifecycle cost; while also maintaining the long-term integrity of their assets. Attendees will learn new methods and techniques to gain an understanding of best practices for an optimally functioning Asset Integrity Management system.

Attendees will benefit from our interactive practical exercises and case studies, while also receiving a firsthand preview of industry-based Technical Integrity Performance Monitoring software. Regardless of attendees’ level of expertise, this course will provide an efficient framework to develop and deploy an Asset Integrity Management Program to take full advantage of the best practices and strengths of your organization.

http://shareholderacademy.com/blog/iconsumer/ceo-bitcoin-december-2017 Who Should Attend?

This course is designed for Vice Presidents, General Managers, Directors, Section Heads, Team Leaders, Senior Managers, Managers, Specialists and Engineers of Asset Integrity Management, Maintenance / Maintenance Planner, Inspection, Quality Assurance / Quality Control, CMMS and Planning Specialist, Machinery Facilities, Integrity and Reliability / Static Reliability, Instrument and Control, Plant Management. From cross-industries, especially: Oil & Gas, Refineries, Petrochemical & Chemical, Engineering, Power & Utilities

http://shareholderacademy.com/blog/iconsumer/ceo-bitcoin-december-2017/ What You Will Gain:

  • Identify the key elements of Asset Integrity
  • Understand the importance of Integrity Assurance
  • Assess whether an Integrity Assurance Framework is present
  • Incorporate how Bow-Tie and Safety Cases are key inputs into an Integrity Assurance Program
  • Acquire the reference integrity related KPIs
  • Explore the need for monitoring Integrity Assurance
  • Determine the key enablers to a sustainable Integrity Assurance Program
  • Describe what AIM is and why it is important
  • Describe the concepts behind AIM and the implementation of IAM system
  • Establish the AIM performance metrics for upstream petroleum production and processing facilities
  • Apply proper principles, procedures and techniques in the selection, design, implementation of AIM system for upstream petroleum industry
  • Analyze the essential components of an AIM system

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http://shareholderacademy.com/blog/tag/offering/ Asset Management and Integrity Theory and Practices

Module 1: Introduction to Asset Identification, Asset Management & Asset Integrity (AI)

  • AI Overview
  • AI Issues
  • Case Studies of AI Failures
  • Asset Management (AM) Theory and Practices
  • Asset Identification – Asset Register, Asset Hierarchy and Bill of Materials (BOMs)
  • Introduction to Basic and Advanced AM Landscape Process Models
  • International standards on AM including ISO 55000, PAS 55, IAM, GFMAM, etc
  • Exercise / Assessment

Module 2: Asset Integrity Strategy & Key Performance Indicators

  • AI Philosophy
  • Integrity Assurance Concepts
  • Bow Tie
  • AI Key Performance Standards (AI KPSs) and their functions
  • Lagging and leading AI KPSs
  • AI KPS tiers and setup
  • Using AI KPSs to drive integrity
  • Implementing AI KPS monitoring and evaluation system
  • Exercise

 Module 3: AI Review Process

  • AI review strategy and preparation
  • AI review process
  • Implementing AI review process
  • Reporting and evaluation of results
  • Exercise

Asset Degradation, Damage & Integrity Life Cycle

Module 4: Asset Integrity Elements, Life Cycle and Barriers

  • Critical Equipment Indicators
  • AI Process and Elements
  • Life cycle of an asset and operational workflow
  • AI Life Cycle – Concept Selection and Definition; Detailed Engineering and Design, Construction and Commissioning; Operations, Modification and Maintenance; Acquisition and Decommissioning
  • AI Barriers
  • Exercise / Assessment

Module 5: Safety Critical Elements and Equipment (SCE)

  • SCE and operational integrity management
  • Safety critical element versus safety critical equipment
  • Major accident hazards
  • Identifying SCE and Performance Standards
  • Asset Integrity Verification, Assurance and ICP
  • Exercise

 Module 6: Asset Degradation and Damage

  • The Way Upstream Petroleum Assets Fail – Deterioration, Degradation and Damage
  • Failure behavior onshore and offshore petroleum production and processing systems
  • Impact of Asset Deterioration, Degradation and Damage
  • The Bathtub Curve
  • Time independent versus time dependent failures
  • Analysis of key degradation and damage threats
  • Exercise

 Life Cycle Asset Integrity Management 

Module 7: Assets Integrity Management (AIM) System

  • AI Threats and Anomalies
  • Design Concepts, Identification and Mitigation Measures
  • System Engineering, RAMS Specification and Life Time Extension
  • Different Approaches to Life Cycle AIM Techniques
  • Role of Inspection and Maintenance in Life Cycle AIM
  • AIM Process and Elements
  • Implementing Functioning AIM System
  • Monitoring and Evaluation of AIM System
  • Exercise

 Module 8: AIM Tools

  • Failure Modes & Effects Analysis (FMEA)
  • Reliability Centered Maintenance (RCM)
  • Risk Based Inspections (RBI)
  • Preventative Maintenance (PM) / Predictive Maintenance (PdM)
  • Management of Change (MOC)
  • Exercise

Module 9: Emergency Repairs

  • Decision Tree Optimization for Inspect/Run/Repair Decisions
  • Emergency Repairs and Loss of Containment
  • Fitness for Service and Defect Assessment
  • Sleeves, Clamps and Mechanical Connectors
  • Composites and Clock Spring
  • Mechanical Replacement
  • Line Stopping and Hot Tapping
  • Exercise

Risk Based Approaches to Life Cycle Asset Integrity Management 

Module 10: Maintenance Excellence

  • Leadership Commitment
  • Maintenance Excellence Concepts
  • Maintenance Performance Indicators
    • Introduction to guidelines and standards
    • Traditional measures used in the oil and gas industry versus future challenges in remote and harsh environments. Latest development
  • The concept of target risk/reliability levels
  • General methodology for risk-based life management
  • Exercise

 Module 11: Risk-Based Inspection & Maintenance of Upstream Petroleum Assets

  • Basic standards for upstream petroleum production and processing systems and equipment
  • Critical assessment model for upstream petroleum production and processing systems and equipment
  • Inspection and Condition Monitoring Technologies
  • RAM Data Management and Analytics Platforms
  • Risk determination and risk-based inspection (RBI)
  • The seven steps of risk-based maintenance (RBM) / reliability centered maintenance (RCM) including failure mode effects and criticality analysis
  • Risk-based system and equipment approach to maintenance
  • Probability of failure (PoF) and consequence of failure (CoF)
  • Contingency planning optimization; RAM and remaining useful life analysis
  • Preventive maintenance and computerized maintenance management systems
  • Exercise

 

Reliability, Availability and Maintainability (RAM) Analysis and Evaluation of Upstream Petroleum Assets

Module 12 – Statistical theory and applications

    • Probability and statistics
    • The most commonly used distributions for product life and their applications
    • 1, 2 and 3-parameter Weibull, mixed Weibull, 1 and 2-parameter exponential, lognormal, normal, generalized gamma
    • Parameter estimation methods and theory
    • Probability plotting, rank regression analysis, maximum likelihood estimation (MLE)
    • Confidence bounds determination
    • Fisher matrix, likelihood ratio and beta-binomial bounds
    • How it is applied and practical examples
    • Case study for assessment of competency against learning objectives

 Module 13 – RAM engineering concepts and analysis techniques

    • RAM analysis overview
    • Preparation of RAM analysis
    • RAM analysis methods
    • RAM performance measures
    • Importance of RAM analysis and performance measures
    • Pareto analysis
    • Key performance indicators analysis
    • Power law model parametric estimation and hypothesis test
    • Computer-based performance simulation, state estimation and forecasting
    • Application of RAM analysis to existing assets to estimate remaining useful life
    • Application of RAM analysis to new technology or product standardization
    • How it is applied and practical examples
    • Case study for assessment of competency against learning objectives

 Module 14 – Failure prognosis and analysis models

    • Failure type detection
    • Physical-based model methodology
    • Knowledge-based model methodology
    • Data driven-based model methodology
    • Predictive maintenance
    • How it is applied and practical examples
    • Case study for assessment of competency against learning objectives

Module 15 – RAM analysis process

    • RAM analysis block diagram
    • Reliability block diagram
    • Fault tree analysis (FTA)
    • Event tree analysis (ETA)
    • Common cause failure analysis (CCFA)
    • Failure rate and mean time between failures
    • The bathtub distribution
    • Down time and repair time
    • Computer-based performance simulation, state estimation and forecasting
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 16 – System reliability assessment

    • Fundamentals of system reliability
    • Fundamentals of reliability block diagrams (RBDs) – series and redundant systems
    • Parallel systems – “k-out-of-n” systems, complex systems, etc
    • System reliability determination
    • System level PDF from component data
    • System failure rate
    • System level reliability function (MTTF), MTTR and availability determination and predictions
    • Utilizing reliability block diagrams for multiple failure mode analysis
    • Reliability of repairable systems
    • Computer-based performance simulation, state estimation and forecasting
    • How it is applied and practical examples
    • Case study for assessment of competency against learning objectives

Module 17 – System maintainability and availability assessment

    • Maintainability fundamentals – quantification and measure
    • Quantifying maintenance costs for system reliability – renewal theory, spares requirement determination
    • Quantifying effects of maintenance policies on reliability, spares, costs, availability, downtime, etc
    • Optimum replacement of system components
    • Understanding life cycle costs and life cycle cost estimation
    • Computer-based performance simulation, state estimation and forecasting
    • How it is applied and practical examples
    • Case study for assessment of competency against learning objectives

Module 18 – RAM modeling and prediction – life data analysis

    • What it is
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 19 – RAM modeling and prediction – standard based prediction

    • What it is
    • Types of standard based predictions
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 20 –Introduction to Failure Modes Effects Analysis (FMEA)

    • Definition and historical background
    • Examine applications and benefits
    • Importance of FMEA as part of design of reliability (DFR) strategy
    • Introduction to the types of FMEA and published standards
    • SAE J1739, A1AG FMEA, MIL-STD-1629A, etc
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 21 – Basic FMEA analysis process

    • Scoping of FMEA analysis
    • FMEA design, system, sub-system and components
    • Preliminary risk assessments
    • Process flow diagrams
    • Framework for data collection
    • FMEA methodology
    • How to evaluate recommended actions
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

Module 22 – Root cause failure analysis (RCFA)

    • RCFA objective
    • Framework for data collection
    • RCFA methodology and data analysis
    • How to evaluate recommended actions
    • How it is applied and practical examples
    • Case study for assessment of competency against learning objectives

 

Applying RAM Analysis and Evaluation of Upstream Petroleum Assets (Subsea Systems; Static Process Equipment-Topside; Rotating Equipment-Topside)  

 Module 23 – RAM Analysis and Evaluation

    • Introduction to RAM
    • Scoping of RAM analysis
    • Framework for data collection
    • QAQC for collected data
    • Definition of product life data types
    • The most applicable distribution for collected data
    • Standards and regulatory requirements for upstream petroleum assets
    • Functional failure analysis and consequence classification
    • RAM design basis, RAM block diagrams and System RAM analysis
    • RAM analysis inputs and outputs
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Pipeline Integrity Management    

 Module 24 – Introduction to pipeline categories

    • Onshore pipeline
    • Offshore pipeline
      • Subsea to offshore host and inter-platform lines
      • Offshore host to landfall or tanker
      • Offshore subsea production system to landfall
      • Landfall to offloading tanker

 Module 25 – Overview of pipeline system design

    • Design pressure
    • Hydraulic analysis, flow assurance and line sizing
    • Calculation of stresses
    • Materials and coatings
    • Corrosion management
    • Cathodic protection
    • Pipeline Route Selection Process
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 26 – Pipeline surveys

    • Pipelines on land
    • Offshore pipelines
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 27 – Introduction to pipeline integrity management

    • Overview of codes used in developing pipeline integrity management plans
    • Pipeline integrity process and elements
    • Overview of pipeline mitigation techniques
    • Risk-based pipeline integrity methodology
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

Module 28 – Causes of pipeline failure

    • Failure statistics and the relative causes of pipeline failures
    • Manufacturing/Fabrication defects in materials of construction
    • Construction defects
    • Failure modes and how pipelines fail (ductile/brittle fracture)
    • Crack initiation and propagation
    • Introduction to external and internal corrosion
    • Environmentally induced cracking (SCC)
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 29 – Pipeline In-Line Inspection

    • In-line inspection system selection
    • Types of tools
      • Magnetic Flux Leakage tools
      • Ultrasonic tools
      • Caliper vehicles
      • Pipeline location vehicles
    • Hydrostatic pressure testing
    • Direct assessment
    • ECDA (External Corrosion Direct Assessment)
    • Determination of re-inspection Intervals
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 30 – Un-inspectable pipelines and direct assessment

    • Options for making pipelines inspectable
    • Direct assessment procedures and methodologies for external corrosion, internal corrosion and stress corrosion cracking
    • Above ground survey techniques
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 31 – Pipeline integrity management planning & tools

    • Introducing the concept of “risk”
    • Risk-based inspection (RBI) in pipeline integrity management
    • Qualitative risk assessment approaches to pipeline integrity management
    • Quantitative risk assessment approaches to pipeline integrity management
    • Probability of failure (PoF) in pipeline integrity management
    • Consequence of failure (CoF) in pipeline integrity management
    • Risk determination in pipeline integrity management
    • Introduction to pipeline lifecycle integrity management strategy
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

Module 32 – Subsea pipeline integrity management planning through risk-based inspection & project cost analysis

    • Current problems with subsea pipeline integrity management
    • Assessing risk of subsea pipeline integrity management
    • Primary threat in subsea pipeline integrity management
    • Common industry assessments
    • Hazard identification (HAZID)
    • Layers of protection analysis (LOPA)
    • Corrosion risk assessment (CRA)
    • Balancing project & operating Costs
    • How it is applied
    • Practical examples
    • Case study for assessment of competency against learning objectives

 Module 33 – Quality Management System Structure and Quality Planning

 Module 34: Work Management Process

  • Identify & Prioritize
  • Work Planning
  • Scheduling
  • Execution & Close Out
  • Analysis / Root Cause Analysis (RCA)
  • Exercise

Module 35: Root Cause Analysis (RCA)

  • Phases
  • Data Collection
  • Assessment

Module 36: Tools & Reporting

  • Types of Measures
  • Key Performance Indicators (KPIs)
  • Trends

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