36311936 P RBI Presentation Slide

MOHD NORHAFIZ BIN OTHMANMECHANICAL ENGINEERINGM9348UTP Supervisor : Dr Redzuan

Host Company Supervisors: Mr Eric Ang Mr Quek Meng Kau

Assalamualaikum and good morning to Dr Redzuan,mr kuek,mr eric and all. Welcome to my industrial training final presentation. Before all that, let me introduce you a bit about my self. My name is mohd norhafiz bin othman. I am currently studied in mechanical engineering department and now going into an industrial training. My existance here today is to give some presentation about what I have done in my 8 month internship.*

ContentTraining ObjectiveProject & ActivitiesProject InvolvementConclusion & AcknowledgementQ & A Session

For today presentation,we will go through all this point. My training objective,project and activites,my project involvement and a Q&A Session.*

Training ObjectiveIntegrate theories with practicalWork side by side with industrial practitionersIntroduction to work cultures and industrial practices.Expose student to potential employeesDevelop skills in communication, work ethics, management, etc.

We come to my training objective. 1)*

Host Company ProfileOil & Gas Management (M) Sdn BhdIncorporated in 2000Objective: Operation in Oil & Gas industryAssist managing for improvement of operation through asset integrityServices:

PRODUCT AND SERVICESIntegrated Specialist Solution Services Advanced NDT Inspection Services Scoop Sampling Risk Based Inspection (RBI)Asset Integrity Management Services (AIM) Plant Reliability Based Mechanical Integrity Operation Reference Planning (ORP)

Impact testingCreep testingTensile Testing

Automatic Ultrasonic Testing (AUT) Acoustic Emission (AE) Online inspection in facilities

I suppose to give some intro about my host company but I think my colleagues ,amirul have done that in his presentation before. So,maybe we can skip it.*

Project & Activities

During my 8 month training, I have been attached at miri branch. A lot of new thing Ive learnt there. This is all my activities during my training in miri. Petronas risk based inspection is a part of knowledge I gathered there. What is PRBI?? We will go details after this. Ive been given responsbilities to work with SBO and focus on Samarang field. For my project, it is located at labuan crude oil terminal(LCOT). Other than that,I also work on oil platform for samarang, bayan and d35 field.*

PMOSKOSBOLCOTProject Involvement

Now come the project that I have been working on during my internship. I basically work with petronas carigali. For your information ,petronas carigali is divided into 3 different region which is PMO,SBO and SKO. All this region have their own crude oil terminal to store their product. for PMO they have TCOT. For SKO, they also have their own which is BCOT and MCOT. For this region which is SBO,they called it LCOT. This is where literally I do my project which is PRBI.*

LCOT Layout

There are a lot of storage tank located in this terminal. All the product that have been successfully drilled offshore will be stored here. So,it is important that the condition of the tank is always in a top level. If not,all the effort of drilling the oil will come to waste. To make sure the tank can contain the oil , an inspection need to be done. This is what my project Is all about. before come to any detail, let me show you what I have been working on. Among these tank, I have been assigned to one tank which isT-1201.( click)*

T-1201 Layout

This is T-1201 layout. This is what my project about. Im assigned to manage the inspection of this tank. but how I am gonna do it????

The answer is..*

P-RBI

PRBI what is prbi???*

Petronas-Risk Based Inspection (P-RBI)A method that have been approved to meet the requirements of API 580 and being used by PETRONAS

Objectives

To focus inspection resources on critical equipment which will prevent failures.

PRBI is an acronym for Petronas Risk Based Inspection. It is a method that developed for evaluating risk and factoring it into decisions concerning how, where , and when to inspect equipment. This method is designed to meet the requirement of API recommended practice 580.

The objectives of P-RBI is to focus inspection resource on critical equipment which will prevent failures for the equipment. And the main output for PRBI is the inspection planning.*

P-RBI BenefitsReduce costsProvide well defined steps to improve plant performanceOptimize inspection ,test and maintenance work.Reduce and ultimately eliminate unplanned equipment failures.

P-RBI Reduces RiskHow??Finding and fixing problem before lead to leaks.An item will be removed from its service if it risk reach unacceptable level.

Of course this software will give benefit to its user. All company want to achieve this first objective. I dont think exist in this world a company that dont want to reduce cost. The second one is to provide well defined steps to improve plant performance. PRBI also optimize inspection, test and maintenance work. This help company to reduce unnecessary visit to offshore to inspect a certain equipment that have high percentage of failure. And unplanned equipment failure also can be reduced and be eliminated by having a detail condition of equipment and know their remaining life.

And what important is PRBI reduces risk. But the question is HOW????? PRBI can reduces risk but not eliminated it. It can be done by finding and fixing problem before lead to leaks. In my project, the leak can cost a big amount of money to the company. But, in another equipment, it failure can cause not only money but also the life of people around it. After that, PRBI will help to detect which item need to be removed form its service if it risk reach unacceptable level.*

P-RBI Implementation StepsIdentify EquipmentCriticality AnalysisInspection PlanningInspection ActivitiesEvaluate ResultsUpdate CriticalityReport ResultsUpdate Inspection PlansNon-conformance

After come withh all the introduction to prbi,let me explain about its implementation steps. first thing first. We need to identify the equipment that we want to analize.in my project, I am incharged of T-1201. (click)

The next step after identify the equipment is data collection. (click)*

Identifying EquipmentTank details:Tank Number: T-1201Tank Type: Upright Cylindrical fixed Storage TankReference Height: 13100Tank Diameter: 11300Max Liquid Level: 12000Design Temp: 65CDesign Press: 56 / -6 mbar

P-RBI On Storage Tank T-1201

This is my tank details. Bla2all this info can we get in General arrangement drawing.*

Data ExampleP-RBI On Storage Tank T-1201

This is the example of data that needed for calculating the criticality of my storage tank. I take all this from General arrangement of T-1201. We can see here we can get the design and operating pressure. It stated also the corrosion allowance and type of material used for building this storage tank. All this can help calculating the criticality and thus manage the inspection planning for T-1201.*

Data CollectionWe get data for the equipment from:General Arrangement (GA)Ultrasound Thickness Test (UT)PFD and P&IDManufacturer Equipment Data Sheet (U-1 Report)

Data Collection PitfallsIncomplete data collectionInappropriate sourceCut and paste errorsIncorrect units of measure


We can get data from various places. General arrangement drawing is one of the places where a lot of data come from. Besides it, we can also use UT bla2 to get our desired data. U-1 report is a form that will be filled by an inspector after they done their inspection to the equipment. With that form, we can update it to prbi for more accurate results.

In PRBI,there are sometimes an incorrect result showed. Many reason why such data collection pitfalls happen. First of all, of course an incomplete data collection. We can also get incorrect result if our data is from inappropriate source. This need to be avoided from happening. Such pitfalls can also happen if cut and paste errors occur. This is always happen during data transfer. People can also confused and forget to change to unit to the desired unit. From all this causes, I can see that almost all of them is from human error. So, to prevent that, we need to be more careful in doing our job and pay more attention to it.*

Equipment History & Visual Inspection = Inspection History Help to establish the level of deterioration Rate of deterioration Confidence Level

Probability of leak is based on how well we know the true condition of the itemP-RBI On Storage Tank T-1201

Equipment history and Visual inspection is categorized in inspection history. Probability of leak is based in how well we know the condition of the item itself. So, we need to have some inspection so that we know the true condition of the equipment and not just based on the design data alone. Inspection history help to establish the level and rate of deterioration. When inspection is being done for several time, the confidence level of the history is increase thus make our result or criticality is more accurate. Criticality for equipment that havent been into inspection is also can be calculated. It just that the confidence level for the calculation is not accurate.*

Corrosion StudyCorrosion study help to understand how the equipment will failIts also used to establish appropriate Inspection Plans


Corrosion study is also included in data collection. Corrosion study help us to understand how the equipment will fail with knowing the damage or deterioration that happening in the equipment which in my case my storage tank. SME will identify likely failure mechanism with expected rates and the inspection data will be reviewed to confirm the predictions. Corrosion study can be used to establish appropriate Inspection Plans. Inspection Planning will add methods to cover uninspected mechanism of the tank. We can see here there are field for expected corrosion rate. We need to calculate this thing in order to get our criticality. This can be done by calculating the different of thickness of two different time and divide it by the number of years. All the data for calculation can be found in NDE template. In my case, I dont have it thus I have to follow what have been set by corrosion specialist. They have calculated the corrosion rate of carbon steel and set it as o.o5mm/year.*


This is windows that shows the data that we fill for calculations. *

Criticality AnalysisProbabilityConsequencesInternal corrosionExternal corrosionCrackingOther damage mechanism

CostEnvironmentalToxic

RISKP-RBI On Storage Tank T-1201

Now I will explain about criticality analysis for my storage tank. Criticality is another word used for risk. Some company are not comfortable in using risk in their operation. Thats why they called it criticality analysis. Risk is a measure of both probability and consequences. We can see here a colourful box filled with number. This is Criticality Matrix. We can use it to identify the risk or criticality for our desired part of equipment. The Red box indicate high level of risk and the pink one indicate medium high. The Yellow and green box means medium and low respectively. If you all noticed, besides the box, there are some number from 1 to 5. the lowest number indicate highest probability vice versa. On the bottom of the box, we can see some letter which is A B C D E. A indicate catastrophic consequences and E is minor consequences. Using some calculation from both probability and consequences we can get criticality for my tank T-1201. I have listed the example of probability and consequences here. Internal corrosion, external corrosion , cracking and other damage mechanism such as fatigue is type of probabilities. For consequences of my tank, its covered for cost, environmental and also toxic. Different equipment have different consequences and probability. So, it is up to the inspector to confirm what it is. For criticality calculator, we only need data for shell and bottom to complete the analysis.*


This is the step for calculating criticality. Right now, I just show shell component of my tank. It is the same for bottom. We need to fill all the required field for the calculation.*

CriticalityP-RBI On Storage Tank T-1201

This is where criticality calculator is located. On top of the matrix, we can see the results of the calculation for the part. In this first page, it only show the result and we can put some comment in this field here. On top of the matrix also, we can see RUN button. We need to click it in order for the software to execute the calculations. If some compulsory field are empty, the field will turns to red and remind us to fill it.*

Internal CorrosionP-RBI On Storage Tank T-1201

For internal corrosion part, there are some compulsory field that need to be fill. *

External CorrosionP-RBI On Storage Tank T-1201

Enviromental CrackingP-RBI On Storage Tank T-1201

ConsequencesP-RBI On Storage Tank T-1201

Production LossP-RBI On Storage Tank T-1201

For production loss, there are different choice depending on the level of loss. For my tank, I choose E because my equipment does not have to be shutdown in order to inspect it. It also does not poses big threat if failure occur during its operation.*

Inspection PlanningRecommended TasksRecommended LocationsDefine Task & LocationsP-RBI On Storage Tank T-1201

Inspection plans are the primary output of an RBI assesment. As I mentioned before, risk is a measure of both probability and consequences. We need to control those two in order to reduce the risk for the equipments. It is hard to control the consequences. But it is a different story for probabilities. We can control it. Thats come the need of inspection which is to control the probability of failure . PRBI help to plan and optimize the inspection for My tank. In the first box, stated there recommended task for our inspection. It tell us what to do and this help preparing for the visit to the equipment later. The second box shows recommended locations. This help inspector to focus on locations that been stated in PRBI. The third box here shows all the task and locations needed to do the inspection . What I can see this help manage the inspection and saving some time and also cost.*

Inspection ManagementVisual InspectionUltrasonic Thickness TestingRadiographyPenetrant Testing

Type of InspectionsP-RBI On Storage Tank T-1201

After inspection planning, of course come to the inspection activities. We need to do the inspection in order to know the real condition of the items. There are several ways to do the inspection and one of them is the most basic , Visual Inspection. Visually, we can get how the condition of an item but it is not accurate compare to other inspection such as UT testing and radiography. Penetrant testing can also be included in visual inspection. Dye will be apply on the surface and we will happen to see the damage that occur on it.*

Non-ConformanceConditions found during inspection that do not meet acceptance criteriaNon-conformance report (NCR) can be generated and tracked in P-RBI


Non- Conformance. While doing the inspection, it is not impossible to come across something that do not meet acceptance criteria. We call this non-conformance. This phenomena can be tracked and generated in P-RBI.*

Report & QueriesP-RBI On Storage Tank T-1201

*

ConclusionSkill enhancedBuilt more confidenceGained professional experienceKnowledge application

Now, come for the conclusion of my 8 month training in OGM. During my stay here, I manage to improved my skill in various aspect such as communication, time management and stress management. Other that that, in the same time, my training here have build more confidence in myself. It stated in my objective that I want to integrate my theories with some real life application. So, it is approved that my industrial training have manage me to do it and in the same time help me gained some professional experience by working with OGM staff.*

AcknowledgmentMr Eric AngMr Quek Meng KauEngineers & TechniciansDr Ridzual

Q & A session

*

Assalamualaikum and good morning to Dr Redzuan,mr kuek,mr eric and all. Welcome to my industrial training final presentation. Before all that, let me introduce you a bit about my self. My name is mohd norhafiz bin othman. I am currently studied in mechanical engineering department and now going into an industrial training. My existance here today is to give some presentation about what I have done in my 8 month internship.*For today presentation,we will go through all this point. My training objective,project and activites,my project involvement and a Q&A Session.*We come to my training objective. 1)*I suppose to give some intro about my host company but I think my colleagues ,amirul have done that in his presentation before. So,maybe we can skip it.*During my 8 month training, I have been attached at miri branch. A lot of new thing Ive learnt there. This is all my activities during my training in miri. Petronas risk based inspection is a part of knowledge I gathered there. What is PRBI?? We will go details after this. Ive been given responsbilities to work with SBO and focus on Samarang field. For my project, it is located at labuan crude oil terminal(LCOT). Other than that,I also work on oil platform for samarang, bayan and d35 field.*Now come the project that I have been working on during my internship. I basically work with petronas carigali. For your information ,petronas carigali is divided into 3 different region which is PMO,SBO and SKO. All this region have their own crude oil terminal to store their product. for PMO they have TCOT. For SKO, they also have their own which is BCOT and MCOT. For this region which is SBO,they called it LCOT. This is where literally I do my project which is PRBI.*There are a lot of storage tank located in this terminal. All the product that have been successfully drilled offshore will be stored here. So,it is important that the condition of the tank is always in a top level. If not,all the effort of drilling the oil will come to waste. To make sure the tank can contain the oil , an inspection need to be done. This is what my project Is all about. before come to any detail, let me show you what I have been working on. Among these tank, I have been assigned to one tank which isT-1201.( click)*This is T-1201 layout. This is what my project about. Im assigned to manage the inspection of this tank. but how I am gonna do it????

The answer is..*PRBI what is prbi???*PRBI is an acronym for Petronas Risk Based Inspection. It is a method that developed for evaluating risk and factoring it into decisions concerning how, where , and when to inspect equipment. This method is designed to meet the requirement of API recommended practice 580.

The objectives of P-RBI is to focus inspection resource on critical equipment which will prevent failures for the equipment. And the main output for PRBI is the inspection planning.*Of course this software will give benefit to its user. All company want to achieve this first objective. I dont think exist in this world a company that dont want to reduce cost. The second one is to provide well defined steps to improve plant performance. PRBI also optimize inspection, test and maintenance work. This help company to reduce unnecessary visit to offshore to inspect a certain equipment that have high percentage of failure. And unplanned equipment failure also can be reduced and be eliminated by having a detail condition of equipment and know their remaining life.

And what important is PRBI reduces risk. But the question is HOW????? PRBI can reduces risk but not eliminated it. It can be done by finding and fixing problem before lead to leaks. In my project, the leak can cost a big amount of money to the company. But, in another equipment, it failure can cause not only money but also the life of people around it. After that, PRBI will help to detect which item need to be removed form its service if it risk reach unacceptable level.*After come withh all the introduction to prbi,let me explain about its implementation steps. first thing first. We need to identify the equipment that we want to analize.in my project, I am incharged of T-1201. (click)

The next step after identify the equipment is data collection. (click)*This is my tank details. Bla2all this info can we get in General arrangement drawing.*This is the example of data that needed for calculating the criticality of my storage tank. I take all this from General arrangement of T-1201. We can see here we can get the design and operating pressure. It stated also the corrosion allowance and type of material used for building this storage tank. All this can help calculating the criticality and thus manage the inspection planning for T-1201.*We can get data from various places. General arrangement drawing is one of the places where a lot of data come from. Besides it, we can also use UT bla2 to get our desired data. U-1 report is a form that will be filled by an inspector after they done their inspection to the equipment. With that form, we can update it to prbi for more accurate results.

In PRBI,there are sometimes an incorrect result showed. Many reason why such data collection pitfalls happen. First of all, of course an incomplete data collection. We can also get incorrect result if our data is from inappropriate source. This need to be avoided from happening. Such pitfalls can also happen if cut and paste errors occur. This is always happen during data transfer. People can also confused and forget to change to unit to the desired unit. From all this causes, I can see that almost all of them is from human error. So, to prevent that, we need to be more careful in doing our job and pay more attention to it.*Equipment history and Visual inspection is categorized in inspection history. Probability of leak is based in how well we know the condition of the item itself. So, we need to have some inspection so that we know the true condition of the equipment and not just based on the design data alone. Inspection history help to establish the level and rate of deterioration. When inspection is being done for several time, the confidence level of the history is increase thus make our result or criticality is more accurate. Criticality for equipment that havent been into inspection is also can be calculated. It just that the confidence level for the calculation is not accurate.*Corrosion study is also included in data collection. Corrosion study help us to understand how the equipment will fail with knowing the damage or deterioration that happening in the equipment which in my case my storage tank. SME will identify likely failure mechanism with expected rates and the inspection data will be reviewed to confirm the predictions. Corrosion study can be used to establish appropriate Inspection Plans. Inspection Planning will add methods to cover uninspected mechanism of the tank. We can see here there are field for expected corrosion rate. We need to calculate this thing in order to get our criticality. This can be done by calculating the different of thickness of two different time and divide it by the number of years. All the data for calculation can be found in NDE template. In my case, I dont have it thus I have to follow what have been set by corrosion specialist. They have calculated the corrosion rate of carbon steel and set it as o.o5mm/year.*This is windows that shows the data that we fill for calculations. *Now I will explain about criticality analysis for my storage tank. Criticality is another word used for risk. Some company are not comfortable in using risk in their operation. Thats why they called it criticality analysis. Risk is a measure of both probability and consequences. We can see here a colourful box filled with number. This is Criticality Matrix. We can use it to identify the risk or criticality for our desired part of equipment. The Red box indicate high level of risk and the pink one indicate medium high. The Yellow and green box means medium and low respectively. If you all noticed, besides the box, there are some number from 1 to 5. the lowest number indicate highest probability vice versa. On the bottom of the box, we can see some letter which is A B C D E. A indicate catastrophic consequences and E is minor consequences. Using some calculation from both probability and consequences we can get criticality for my tank T-1201. I have listed the example of probability and consequences here. Internal corrosion, external corrosion , cracking and other damage mechanism such as fatigue is type of probabilities. For consequences of my tank, its covered for cost, environmental and also toxic. Different equipment have different consequences and probability. So, it is up to the inspector to confirm what it is. For criticality calculator, we only need data for shell and bottom to complete the analysis.*This is the step for calculating criticality. Right now, I just show shell component of my tank. It is the same for bottom. We need to fill all the required field for the calculation.*This is where criticality calculator is located. On top of the matrix, we can see the results of the calculation for the part. In this first page, it only show the result and we can put some comment in this field here. On top of the matrix also, we can see RUN button. We need to click it in order for the software to execute the calculations. If some compulsory field are empty, the field will turns to red and remind us to fill it.*For internal corrosion part, there are some compulsory field that need to be fill. *For production loss, there are different choice depending on the level of loss. For my tank, I choose E because my equipment does not have to be shutdown in order to inspect it. It also does not poses big threat if failure occur during its operation.*Inspection plans are the primary output of an RBI assesment. As I mentioned before, risk is a measure of both probability and consequences. We need to control those two in order to reduce the risk for the equipments. It is hard to control the consequences. But it is a different story for probabilities. We can control it. Thats come the need of inspection which is to control the probability of failure . PRBI help to plan and optimize the inspection for My tank. In the first box, stated there recommended task for our inspection. It tell us what to do and this help preparing for the visit to the equipment later. The second box shows recommended locations. This help inspector to focus on locations that been stated in PRBI. The third box here shows all the task and locations needed to do the inspection . What I can see this help manage the inspection and saving some time and also cost.*After inspection planning, of course come to the inspection activities. We need to do the inspection in order to know the real condition of the items. There are several ways to do the inspection and one of them is the most basic , Visual Inspection. Visually, we can get how the condition of an item but it is not accurate compare to other inspection such as UT testing and radiography. Penetrant testing can also be included in visual inspection. Dye will be apply on the surface and we will happen to see the damage that occur on it.*Non- Conformance. While doing the inspection, it is not impossible to come across something that do not meet acceptance criteria. We call this non-conformance. This phenomena can be tracked and generated in P-RBI.*

*Now, come for the conclusion of my 8 month training in OGM. During my stay here, I manage to improved my skill in various aspect such as communication, time management and stress management. Other that that, in the same time, my training here have build more confidence in myself. It stated in my objective that I want to integrate my theories with some real life application. So, it is approved that my industrial training have manage me to do it and in the same time help me gained some professional experience by working with OGM staff.*

*

Documents

36311936 P RBI Presentation Slide