Sgs Ind Aim Us Brochure en 11

7/27/2019 Sgs Ind Aim Us Brochure en 11

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WWW.SGS.COM/AIM

ASSet InteGrIty MAnAGeMentPArtnerInG tO AChIeve yOur InSPeCtIOn, enGIneerInG, dAtA MAnAGeMent And SAfety GOAlS



ASSet InteGrIty MAnAGeMent - AIM

An asset has integrity when it is operated

and maintained so that the combination o

the likelihood o ailure and the consequence

o ailure makes the risk to people, to the

environment, and to the company as low

as reasonably practical.

Plant integrity, saety, and reliability are

major concerns to all plant operators and

managers. The primary objective o Asset

Integrity Management (AIM) is to maintain

the asset in a t-or-service condition while

extending its remaining lie in the most

reliable, sae, and cost-eective manner.

In addition to regulatory and company

requirements, operators o acilities and

pipelines have the ollowing business

needs

n Maximizing production

n Reducing lost income due to

unplanned shutdowns

n Optimizing inspection andmaintenance costs

n Maximizing asset value

n Maintaining an auditable system

Most o our clients already have some

orm o Asset Integrity Management

program in place. However, with

increased regulatory oversight, increased

operating costs, and limited available

resources, implementation o a ully

compliant program is increasingly

challenging or most organizations.

SGS is able to eectively partner with

our clients to help them overcome these

challenges.

SGS AIM experts provide customized

solutions at any level o the development

and implementation process.

PrOGrAM develOPMent

SGS has extensive experience in

developing and documenting risk-

based, time-based, and condition-based

inspection programs or regions all over

the world. Our programs meet API-580,

API-581, PAS 55 and other appropriate

requirements as applicable.

PrOGrAM MAnAGeMent

SGS has experienced project managers

and engineers who can oversee all

aspects o the project. Our personnel arealso able to handle the management o

change process necessary to transition

rom time-based or condition-based to

risk-based inspection programs.

reSOurCeS tO IMPleMent the

PrOGrAM

SGS can participate in implementation

at any level, rom turn-key program

development and implementation to

simple gap-lling services. Our inspectors

are ull-time employees trained in our

saety and quality methodologies. We

provide a ull range o NDT services

including advanced inspection techniques.

SGS experts provide a comprehensive

scope o tness-or-service assessments

including determination o damage

mechanisms. We can oer stand-alone

CAD drawing packages to support

client-based or third-party inspection

programs and provide a unique set o

value adding methodologies including

data management services, electronic

document management, and eld

inspection data collection tools.

PrOGrAM GAP AnAlySIS

SGS experts assist our clients in identiying

the gaps between their program needs and

current implementation.

SGS understands the importance o

insuring the availability o the real time

Key Perormance Indicators (KPI) that

are critical to successul programs.



InteGrAted APPrOACh tO AIM

Verication/Certication o

n Emergency Escape

and Rescue System

n Emergency Shutdown

System

n Fire and Gas Detection

System

n Fire and Lightning

Protectionn Security System

n Design Verication/

Certication

n Regulatory

Compliance

n Risk Assessment

(Hazop)

n Fitness or Service (FFS)

Assessment

n Material Propertiesn Finite Element Analysis

n Mechanical Integrity Management

n Pipeline Integrity Management

n Remaining Lie Calculations

n Data Gathering and Field Inspections

n Risk Based Inspection

n Regulatory Compliance

n Inspection and Maintenance Planning

n Non-Destructive and Material Testing

n Document Management and

Control

n Pas 55 - Asset Management

System Certication

deSIGn SAfeGuArdInG

SySteMS

MAIntenAnCe &

InSPeCtIOn

SGS has implemented hundreds o Asset Integrity Management programs worldwide, including nearly two hundred Risk-based

Inspection (RBI) programs. We have ound that although there are similarities among all o the programs, no two programs are identical.

We put our breadth o knowledge, born rom our extensive experience, to work or each o our clients to provide customized solutions or

their unique needs.

Successully implementing an AIM system requires the right combination o design, engineering, and operational

integrity. SGS partners with our clients to provide exactly the level o services they need. These services can

range rom complete turn-key program design and implementation to simple gap-lling to complement a clients

existing AIM program. The diagram below shows the scope o services which SGS provides its clients.



SGS has been a leader in development

and implementation o comprehensive

programs to comply with OSHA’s Process

Saety Management standards since theirintroduction in 1992.

SGS’ engineering sta at our Asset Integrity

Management Competence Center are

entirely ocused on mechanical integrity

services.

SGS engineers ensure that Recognized

and Generally Accepted Good Engineering

Practices (RAGAGEP) are ollowed and

provide assistance, inspection, and

evaluation based on recognized standards

n ASME Boiler & Vessel Codes

(Sec VIII Div I & II)

n ASME Piping Codes (B31.1, B31.3,

B31.4, B31.8)

n Pressure Vessel Inspection (API 510)

n Pressure Piping Inspection (API 570)

n Pressure Relie Systems (API 520/526)

n Tank Evaluations (API 620/650/653)

n Risk-Based Inspection (API 580/581)

n Fitness or Service (API 579)

n Damage Mechanisms (API 571)

The Competence Center or Asset Integrity

Management’s engineering team specialize

in a variety o disciplines and oer a complete

range o engineering services, including

the ollowing

deSIGn ServICeS And COMPOnent

AnAlySIS

The SGS AIM team has a vast experience

in new equipment design, pressure vesselcomponent analysis and pipe stress

analysis.

The engineers perorming the analysis have

extensive knowledge and experience in

ASME and international standards, with

capabilities such as

n Perorm new equipment design and

pressure vessel component analysis

using popular sotware as per clients

needs

n Analyzing pressure relieving systems

n Perorm intense analysis as per Div II

and include stress maps or the dierent

components o the equipment using

nite element analysis

n Customized engineering analysis

fItneSS fOr ServICe ASSeSSMentS

SGS AIM Engineering provides customized

and cost eective assessments or the

FFS issues and challenges that are common

in rening, upgrading, chemical, paper &

pulp, and gas processing acilities.

Over the last ve years SGS has conducted

over 12,000 assessments o pressure

vessels, piping, and storage tanks in

accordance with API 579-1/ ASME FFS-1.

Key eatures o our FFS assessments

include

n The ability to utilize advanced

techniques such as nite element

analysis to assess equipment

n Industry leading turnaround or the

FFS assessments meaning reduced

shutdown time, and more eective

remediationn Extensive practical experience which

allows SGS to recommend practical

solutions to dicult FFS problems

n Identication o alternate service

options which could allow operation

with enhanced equipment perormance

n Recommendation o eective

remediation and repair approaches

rISK ServICeS

SGS Reliability and Risk Management

Program (RRMP) can be linked with

existing inspection programs both locallyand globally.

The program provides improved

eectiveness o existing programs through

n Providing emphasis on lean inspection

strategies, saety compliance, ailure

prevention and ocus on critical

components

n Damage mechanism review and

assessment

n Identiy the existing risk category

and provide cost eective measures

through inspection program to reduce

and contain the risk

n Review and compile historical inspection

data in preparation or or in support o

RBI implementation

n Assist in acquisition o Owner/User

commissions

fIXed eQuIPMent deGrAdAtIOn

MeChAnISM ServICeS

SGS AIM engineering department includes

engineers with experience evaluating

damage mechanisms or equipment

including pressure vessels, pressure

piping, storage tanks, heat exchangers,

heaters, and specialized equipment.

This includes on-stream assessment as

well as investigation o root causes o

major industrial accidents.

SGS AIM can provide support services

or identication o xed equipment

degradation mechanisms

n Identiying degradation devices eecting

the reliability o xed equipmentn Recommending acceptable criteria

or degradation devices to become

eective

n Recommending lean inspection

strategies, inspection plans and critical

inspection locations

n Identiying internal as well as external

corrosion ranges

enGIneerInG ServICeS

API-579 ffS

evAluAtIOnS

fIeld

InSPeCtIOn

ServICeS

tOOlS &ServICeS

API 580 rBI

ServICeS

ASMe SeC

vIII dIv I &

II deSIGn

ServICeS

fInIte

eleMent

& StreSS

AnAlySIS

API-571

dAMAGe

MeChAnISMS

API 650, API

653 & API 620



n Dening eect o high temperature

and erosion

n Preparing detailed reports

describing type o degradation

mechanisms, eect o degradation

mechanisms, process streams, mass

balance etc.

n Identiying active and accurate

degradation mechanisms or

implementation in risk based

inspection and tness or service

n Provide customized reports to show

the balance o cost and eectiveness

or the degradation mechanisms under

review

fInIte eleMent AnAlySIS (feA)

SGS oers the complete range o FFS

assessments rom initial assessment

through Level III (Finite Element) analysis,

as well consulting or cause and eect

analysis.

Using the most current technology, SGS

engineering experts have the ability to

utilize advanced techniques such as nite

ASSeSSMent And AnAlySIS

element analysis to assess equipment.

Our industry leading FFS assessments

mean reduced shutdown time, and more

eective remediation.

Key eatures o FEA

n Develop 2D and 3D models

o pressure vessel and piping

systems

n Analyze external loads on nozzles

n Evaluate load cases that contribute to

ailure in piping and pressure vessel

components

n Analysis capabilities: Linear, material

non-linear, steady state transient

thermal, stress stiening

n The nozzle evaluation reports include:

allowable loads, fexibility actors,

stress intensication actors

n Compare the results with acceptance

criteria listed in ASME Sec VIII Div I & II

n Perorm atigue calculations or piping

and pressure vesselsn API-579 Level 3 Assessment

n Sel contained, 3D viewer is provided to

the client or reviewing the results

ABOve GrOund StOrAGe tAnK ServICeS

Our experience in engineering services

include veriying new tank design

constructed to API 650, API 620, UL-142

and API 2000.

Comprehensive analysis and reporting

capability including

n Maximum ll height

n Settlement

n Uplit

n Wind loading

n Venting requirements

n Nozzle loadings

n Frangible roos

InSPeCtIOn/

COMPlIAnCe

dAtA

MAnAGeMent

enGIneerInG

APPlICAtIOn

develOPMent



Key PerfOrMAnCe IndICAtOrS

Key perormance indicators are an output o

inspection program and remediation o prog

fACIlIty InSPeCtIOn drAWInG PACKAGe

Available in the system in block style or single line isometric orm - Linked to

acilitate access

InSPeCtIOn drAWInGS

Generated and loaded into the MIMS system or

immediate accessibility

InSPeCtIOn dOCuMentAtIOn

Entered into the MIMS system - Readily accessible by

authorized users

eQuIPMent dOCuMentAtIOn

Entered into the MIMS system - Available to veriy compliance with

applicable requirements

vISuAl InSPeCtIOn dAtA

Entered into the MIMS system - Allows tracking o ndings

and their remediation

COrrOSIOn MOnItOrInG InSPeCtIOn dAtA

Generated and entered into the MIMS system - Actionable

drawings can be readily created

reGulAtOry dOCuMentAtIOn

Entered into the MIMS system - Available or

verication and audit

M

dAtA MAnAGeMent SOlutIOnS

Even moderate scale Asset Integrity

Management programs produce massive

quantities o data that must be eectively

managed. Because the databases that

result rom AIM implementations can beso large, even simple data entry tasks can

involve so many data points that they

overwhelm even well staed inspection

departments.

Furthermore, most standard corrosion

monitoring sotware packages are limited

in their ability to accept, let alone correlate

the ull range o supporting documents

and inormation required or compliance.

And almost none o the standard

packages can automatically link data in

the database to CAD drawings or ield

sketches.

Another signiicant weakness o

standard systems is that they typically

only identiy visual observations as open

or closed, and provide no eective means

to track whether or not the remediations

are completed within the client’s deadlines.

SGS provides services which can addressthese common data management issues.

SGS data analysts provide expert corrosion

data entry support to our clients using

a wide range o commercial sotware

packages including SAP, IBM Maximo,

UltraPIPE, PCMS, Credo, etc. As a result,

SGS has the lexibility to support our

clients existing programs, rather than

compel them to adopt a restricted

corrosion monitoring sotware approach.

In addition, through specialized protocols,

SGS data analysts have successully linked

the corrosion monitoring data in standard

industry sotware to ield sketches,

CAD drawings, and even photographs.

This process provides our clients’ inspection

and maintenance personnel with actionable

drawings without having to go through

the traditional process o hand marking

inspection due and retirement due

drawings based on paper inspection

reports. This SGS method improves theaccuracy o the resulting drawings relative

to traditional methods while actually

reducing the time to produce the required

documents.

SGS can also provide a Mechanical

Integrity Management System (MIMS)

which interaces with the client’s existing

corrosion monitoring sotware. The SGS

MIMS is a web-based application which

acilitates data entry, tracking o visual

observations, reporting o key perormance

indicators, and electronic document

management. The below gure shows

the principle o our MIMS and gives an

overview o data entries and output

deliverances.



em. They provide a critical management tool to track the implementation o the

hich are not readily available through standard corrosion monitoring databases.

rePOrtInG

Provides comprehensive client customisable reports are available in

the MIMS system

InSPeCtIOn & MAIntenAnCe PlAnnInG

Contains tools to automate ormerly labor intensive processes and achieve

signicant cost and quality improvement

COrrOSIOn MOnItOrInG

Provides access to data by site, type, inspection activity and otherclient specic approaches

eleCtrOnIC dAtA MAnAGeMent

Provides organisation and immediate access to

all primary documents

reCOMMendAtIOn trACKInG SySteM

Identies, locates, prioritises, documents and tracks remediation

or all visual observations

M S

The data entry portion o MIMS

automatically distributes data into

industry standard databases, eectively

reducing repetitive data input. In addition,

built-in error checking prevents commonerrors, such as accidental entry o

duplicate circuits within a database, and

thickness reading values inconsistent with

standard piping sizes.

The recommendation tracking portion o

MIMS tracks the status o each visually

observed condition and recommendation.

These can be searched and displayed by a

wide variety o criteria including location

(geographical, unit, GPS coordinates),

priority, status (open or closed), specic

condition, equipment type, maintenance

class (maintenance or repair), and many

others.

The Key Perormance Indicator (KPI)

portion o MIMS displays in real-time

the status o the AIM program

implementation using client dened

measurements. Most clients nd the

display o the status o the visual

observations and recommendationsamong the most useul KPI’s. Typically

these include a scorecard showing the

status o recommendations resulting rom

the visual observations. The scorecard

displays the total number o observations

made by priority, the number o open

conditions, the number o closed

conditions, and the number overdue.

The electronic document management

portion o MIMS provides rapid access to

critical primary documents associated

with pressure vessels and tanks. For

pressure vessels, the system provides

web-based data screens displaying key

manuacturer’s data and documents or

the vessel, as well as an automated gap

assessment or the completeness o the

vessel’s documentation. Similarly, or

tanks, the system automatically provides

a gap analysis as to the completeness and

availability o regulatory agency required

tank documentation. This MIMS eaturesubstantially improves the AIM program’s

robustness or audit.

The MIMS system also works in

cooperation with most RBI sotware

programs to assist in the organisation o

the data at the RBI program inception,

as well as tracking o the data and

inspections during the RBI

implementation.

SGS AIM implementation experts are

ready to assist our clients at their point

o need with these data management

solutions, without requiring a change in

corrosion monitoring sotware or RBI

systems.



rISK-BASed InSPeCtIOn - rBI

Risk-based inspection is an approach to

Asset Integrity Management which seeks

to optimize inspection activities based

on the likelihood and consequence o

ailure o components and systems.

Using this methodology, inspection

requency is highest or the highest risk

systems, and the interval between

inspections is lengthened or those

systems which have the lowest risk.

This common-sense approach to

inspection can signicantly increase

a plant’s on-stream availability, reduce

costs and un-planned downtime.

The primary objectives in implementing

an RBI program are to produce an

inspection strategy that clearly states

WhAt: The equipment that needs to be

inspected

When: The optimum interval betweeninspections

hOW: Speciy the right technique to

detect the deects that a particular

component is most likely to develop

SGS has implemented nearly two hundred

RBI programs world-wide since 1989. Unlike

most service providers who are tied to a

single RBI sotware solution, SGS has

implemented programs using nearly

every major commercially available RBI

sotware program. We match the program

to our client’s unique needs, rather than

orcing them to adopt a solution which is

convenient to us.

SGS partnerships with several established

RBI sotware providers grant customized

systems to deliver the most eective

solutions or data gathering, management,

and analysis. O course, the solution SGS

supplies is compliant with all applicable

governing regulations and guidelines (e.g.

API-580, PAS-55).

In a typical RBI project, SGS will

n Establish the qualitative or quantitative

risk-ranking level o existing equipment,and determine the respective risk

acceptance level based on standard

industry practice and customer dened

criteria

n Assess the process operations

which impact production, mechanical

integrity, and rates o corrosion or

degradation

n Review technical specications and

materials o construction, and provide

gap analysis, recommendations, and

turn-around prioritization

n Identiy risks associated with

equipment degradation and corrosion

rates using industry standards, such as

API-580, API-579, and API-581

n Determine remaining lie or each

component, and determine the

appropriate inspection intervals

n Speciy the necessary inspection and

maintenance tasks and intervals based

on the risk proles



fIeld InSPeCtIOn CAPABIlItIeS

SGS provides clients with dedicated,

ull-time eld inspectors who hold global

and local certications including API, EN,

and ASNT. These inspectors are trained

in SGS saety and quality methodologies

to provide the highest level o service.

SGS’ world-wide AIM service network

provides our clients with access to a ull

range o NDT services including Rope

Access.

SGS has developed several value adding

methodologies and tools which can

signicantly improve the quality and

cost-eectiveness o the inspections.

One o these methodologies is the

use o pre-approved terms or visually

observed conditions and corresponding

recommendations or inspections.

Using this approach, SGS inspectors

and engineers work together with our

client’s inspection, engineering, andmaintenance departments to dene a set

o typical visually observed conditions.

In most cases, approximately 95% o

the conditions or API-510, 570, and 653

inspections can be described by as ew

as 150 to 200 distinct conditions. The

conditions are then prioritized with

respect to likelihood and consequence

o ailure, and the time required or

remediation dened by the client.

For each prioritized condition, a standard

recommendation is developed which is

consistent with the client’s maintenance

philosophy. This approach provides

several signicant advantages. Since

each inspection nding is not treated

as an independent nding, the process

o prioritization, classication, and

recommendation is signicantly

accelerated. Furthermore, standardized

conditions allow analysis o the data,

revealing systemic mechanical integrity

issues.

SGS has also developed an advanced

eld data collection system utilising eld

hardened tablet computers. Inspectors

equipped with these systems can load

photographs, eld sketches, or CAD

drawings o the equipment being

inspected into the tablet computer.

Thickness readings and visual inspection

data can then be entered into the tableteither using handwriting recognition, or

an on-screen keypad. The data collected

is linked to the monitoring locations on

the images. When photographs are

used, the locations o the readings and

visually observed conditions can be

unambiguously identied. In addition,

by using standardized conditions, the

sotware prompts the inspector to

provide the complete inormation needed

to ully address the situation. This both

improves the quality o the data that is

collected, and reduces the project cost

by eliminating the need to return to the

inspection site to collect the required

data. The data collected using this

system can be exported to standard

sotware packages, including MS Excel,

computerized maintenance management

systems like SAP and IBM Maximo, as

well as standard corrosion monitoring

databases, such as UltraPIPE, PCMS,

Credo, etc.

In addition to standard inspection

methods, SGS special examination and

consulting teams are at your disposal

or complex non-destructive testing

requirements. Our broad range o

experts and equipment oers the most

cost-eective and technically appropriate

methods or your unique needs.

Rope Access techniques provide a costeective alternative to traditional access

methods, such as scaolding or mobile

elevated working platorms. Using

Rope Access, inspections can be carried

out quickly and saely with minimal

disruption to other services. All SGS rope

access training and operational work

is conducted in line with International

Guidelines. SGS is member o and

accredited by IRATA (Industrial Rope

Access Trade Association).



nOn-deStruCtIve teStInG ServICeS

Non-Destructive Testing (NDT) is the most

eective and applied testing method o

examining the integrity o an object,

material or a system without reducing its

longevity. In alignment with our

multidiscipline approach to Mechanical

Integrity Management, SGS Industrial

Services oers Radiographic Testing (RT)

to our list o Non-Destructive Testing (NDT)

services.

Understanding that talent, service and

responsiveness is conveyed at the local

level we strive to provide best in class

NDT services to our regional partners.

SGS Technicians are local, ull-time

employees, prepared to provide you with

the highest level o proessional customer

ocused service in the industry. Their goal

is to provide you with timely, thorough and

accurate inspections with repeatability.

SGS uses current up to date technology to

service your radiography needs. Using

industry leading radiography equipment

and exposure devices, and a feet o ully

customized portable x-ray labs, we can

oer our clients the best service and

results, the industry has to oer.

SGS is committed to providing NDT

services or abrication, pipeline, plant

construction & maintenance, chemical &

petrochemical plants, conventional &

nuclear power plants. We can oer ully

unctional and locally managed oces,

strategically located to oer customer

centered NDT services or our clientele.

ndt ServICeS

nRadiographic Testing (RT)

- Detects surace and subsurace

deects with a permanent record

n Ultrasonic Testing (UT)


deects and measures thickness

n Penetrant Testing (PT)

- Detects surace deects with

contrasted visual inspection

n Magnetic Particle Testing (MT)


deects or contrasted visual

inspection

n Positive Material Identication (PMI)

- Determines elemental composition o

unknown materials



■ 100 offices

100 laboratories

in North America

■ 80 offices

70 laboratories

in Latin America

■ 100 offices

80 laboratories

in Africa/Middle East

■ 270 offices

150 laboratories

in Europe

Geneva

■ 160 offices

200 laboratories

in Asia/Pacific

SGS IS the GlOBAl leAder And InnOvAtOr In InSPeCtIOn, verIfICAtIOn, teStInG And CertIfICAtIOn ServICeS. fOunded In

1878, SGS IS reCOGnIzed AS the GlOBAl BenChMArK In QuAlIty And InteGrIty. WIth MOre thAn 64,000 eMPlOyeeS, SGS

OPerAteS A netWOrK Of Over 1,250 OffICeS And lABOrAtOrIeS ArOund the WOrld.

SGS InduStrIAl ServICeS, COMPetenCe Center fOr ASSet InteGrIty MAnAGeMent (AIM)

406 West US Highway 60, Bartlesville, OK 74005, USA, T +1 (888) 215 2671, F +1 (918) 332 - 3197, [email protected]

WWW.SGS.COM/AIM



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Sgs Ind Aim Us Brochure en 11