VAIL-Plant PEMS User Manual

VAIL-PLANT

(RBI & INTEGRITY MANAGEMENT SYSTEM)

VAIL-Plant® Version 14.8.14.1

PRESSURIZED EQUIPMENT MANAGEMENT SYSTEM

(PEMS)

USER MANUAL

Engineering For a Safer World

VAIL-Plant v 14.8.14.1 User Manual

Prepared by : Amee Trivedi Reviewed by: Gulzar Ahmad Page: Page 2 of 94 Approved by : Shahid Javed Kalair Date : April 2015 Revision : 1.4

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Table of Contents

1 PURPOSE .................................................................................................................................................. 4

2 SOFTWARE SUPPORT ................................................................................................................................ 5

3 SYSTEM REQUIREMENTS ........................................................................................................................... 6

3.1 APPLICATION SOFTWARE REQUIREMENTS ................................................................................................................. 6 3.2 HARDWARE REQUIREMENTS ................................................................................................................................... 7

4 SOFTWARE INSTALLATION ........................................................................................................................ 8

5 SOFTWARE STARTUP ................................................................................................................................. 8

5.1 STARTUP............................................................................................................................................................. 8 5.1.1 User Login .............................................................................................................................................. 9

5.2 DASHBOARD ...................................................................................................................................................... 10

6 VAIL‐PLANT INTERFACE ............................................................................................................................ 11

6.1 BUTTON RIBBON FUNCTIONS ................................................................................................................................ 12 6.1.1 PEMS (Pressurized Equipment Management System) ......................................................................... 13 6.1.2 COMPANY Button ................................................................................................................................ 13 6.1.3 LOG OFF Button ................................................................................................................................... 13 6.1.4 CLOSE Button ....................................................................................................................................... 13

6.2 USER DETAILS .................................................................................................................................................... 13 6.3 OUTLOOK BAR ................................................................................................................................................... 14 6.4 NAVIGATION TREE .............................................................................................................................................. 15

6.4.1 Applying Tree Filter .............................................................................................................................. 18 6.5 VIEWS NAVIGATOR ............................................................................................................................................. 19

7 PEMS MODULE (PRESSURIZED EQUIPMENT MANAGEMENT SYSTEM) ....................................................... 20

7.1 PEMS FORM VIEW ............................................................................................................................................ 20 7.1.1 Form View Toolbar ............................................................................................................................... 20

7.1.1.1 Trends ........................................................................................................................................................ 21 7.1.1.1.1 Leaks trend ........................................................................................................................................... 23 7.1.1.1.2 Defects Trend ....................................................................................................................................... 24 7.1.1.1.3 Risk Trend ............................................................................................................................................. 25 7.1.1.1.4 Replacements Trend ............................................................................................................................. 26 7.1.1.1.5 Corrosion Rate Trend ............................................................................................................................ 27 7.1.1.1.6 Metal Loss Trend .................................................................................................................................. 28 7.1.1.1.7 Remnant Life Trend .............................................................................................................................. 29 7.1.1.1.8 Anomalies Trend ................................................................................................................................... 30

7.1.1.2 Drawings .................................................................................................................................................... 31 7.1.1.3 Engineering Data ........................................................................................................................................ 33 7.1.1.4 New button ................................................................................................................................................ 34 7.1.1.5 Save Button ................................................................................................................................................ 40 7.1.1.6 Edit Button ................................................................................................................................................. 41 7.1.1.7 Delete Button ............................................................................................................................................. 41 7.1.1.8 Drop Button ............................................................................................................................................... 41 7.1.1.9 Calculate Button ........................................................................................................................................ 42 7.1.1.10 KPI Calculator ............................................................................................................................................. 42 7.1.1.11 Review Button ............................................................................................................................................ 43 7.1.1.12 Approve Button .......................................................................................................................................... 43



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7.1.1.13 Record Info Button ..................................................................................................................................... 43 7.1.1.14 Advanced Search ........................................................................................................................................ 44

7.1.2 Form View “Search Combo box” .......................................................................................................... 47 7.1.3 Form View Record Navigator ............................................................................................................... 51 7.1.4 Form View Tabs.................................................................................................................................... 52

7.1.4.1 Equipment Main Data ................................................................................................................................ 52 7.1.4.2 Engineering Data Tab ................................................................................................................................. 53 7.1.4.3 Third Party RBI Results Tab ........................................................................................................................ 54 7.1.4.4 Velosi RBI Tab ............................................................................................................................................ 54 7.1.4.5 Inspection Plan ........................................................................................................................................... 67 7.1.4.6 History Records Tab ................................................................................................................................... 67 7.1.4.7 Condition Monitoring Tab .......................................................................................................................... 71 7.1.4.8 Inspection Results Tab ............................................................................................................................... 72

7.2 PEMS LIST VIEW ............................................................................................................................................. 74 7.2.1 Grid Header .......................................................................................................................................... 75 7.2.2 Sorting of Records ................................................................................................................................ 75 7.2.3 Sorting Upward .................................................................................................................................... 75 7.2.4 Sorting Downward ............................................................................................................................... 76 7.2.5 Records Filtering .................................................................................................................................. 76 7.2.6 Exporting to Excel ................................................................................................................................ 77 7.2.7 List View’s Buttons in the Outlook Bar ................................................................................................. 78

7.2.7.1 Engineering Data ........................................................................................................................................ 78 7.2.7.2 Third party RBI Results ............................................................................................................................... 79 7.2.7.3 Velosi RBI ................................................................................................................................................... 80 7.2.7.4 Inspection Plan ........................................................................................................................................... 80 7.2.7.5 Logistics Requirements .............................................................................................................................. 81 7.2.7.6 History Records .......................................................................................................................................... 82 7.2.7.7 Inspection Results ...................................................................................................................................... 82

7.3 PEMS REPORT VIEW ...................................................................................................................................... 83 7.4 PEMS USER LIST VIEW .................................................................................................................................... 85

7.4.1 How to create a new query? ................................................................................................................ 86 7.4.2 How to delete an existing query? ......................................................................................................... 90 7.4.3 How to export the results to excel file? ................................................................................................ 90

7.5 REFERENCE DOCUMENTS .............................................................................................................................. 90



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1 PURPOSE

The purpose of this document is to present a clear and concise procedural outline for using

PEMS module of VAIL-Plant version 14.8.14.1 so that the user may be able to utilize all its

features. We have listed step-wise procedures for performing tasks along with screenshots to aid

practical understanding.

This document details the methods of using features of the module such as viewing, searching

and updating equipment data, calculating equipment risk, performing semi-quantitative RBI,

managing equipment history of inspections, failures and replacements, reviewing/ approving the

addition and modification of equipment or its components, creating risk based inspection plans,

viewing reports, generating dynamic reports etc.

It is assumed that the operator is familiar with MS Windows, MS Office and so this is not

covered in this document.



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2 SOFTWARE SUPPORT

User can contact Velosi for software support on technical issues for VAIL-Plant by following contact details:- Contact Person: Gulzar Ahmad (Sr. Software Engineer) Email ID: [email protected] Office Address: VELOSI ASSET INTEGRITY LIMITED, Marina Plaza Building, Suite No. 402, P.O. Box: 114192, Abu Dhabi (UAE) Website: www.applusvelosi.com Telephone: +971 2 6349815 Fax: +971 2 6349816



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3 SYSTEM REQUIREMENTS

This section details the system requirements on both the server and client sides in order to run VAIL-

Plant.

3.1 Application Software Requirements

There are two different options for deploying VAIL-Plant on the server and client. Both options

have been detailed below.

1) VAIL-Plant installed on server

For this option, the VAIL-Plant Application software will be installed on a Server and the client machines

will run this installation from a shortcut to a network drive.

Server Side Software Requirements

VAIL-Plant application

SQL Server 2005 Express Edition or Above

Microsoft Windows Server 2003 or above

Microsoft Chart Controls 3.5.0 or higher

Crystal Reports 10.0

Microsoft office package 2003 or higher as utility for data exporting and reporting purposes

Client Side Software Requirements

Microsoft Windows XP (Service Pack 2), Vista or 7

Microsoft .Net Framework 3.5 or above

Microsoft Charts

2) VAIL-Plant installed on each PC

For this option, the VAIL-Plant Application software will be installed on each client machine.

Server Side Requirements

SQL Server 2005 EE OR Above

Microsoft Windows Server 2000 or above

Client Side Requirements

Microsoft Windows XP (Service Pack 2), Vista or 7

Microsoft office package as utility for data exporting and reporting purposes

Microsoft .Net Framework 3.5 or above



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VAIL-Plant application

Microsoft Chart Controls 3.5.0 or higher

Crystal Reports 10.0

Microsoft office package 2003 or higher as utility for data exporting and reporting purposes

3.2 Hardware Requirements

Application Hardware Requirements

Below are the minimum hardware requirements for running VAIL-Plant application:

Pentium class processor, 2.1 GHz (recommend Core i3 Class)

1 GB Available RAM (recommended 2 GB)

1 GB hard drive space minimum on installation drive (recommended 50 GB)

Database Hardware Requirements

The VAIL-Plant Database will store a lot of information, and will increase in time. Attached documents

can be stored within the Database using BLOB and CLOB fields. They can also be stored out-with the

database. If storing documents in the Database, the size of that Database is likely to increase considerably.

Therefore, it is impossible to determine exactly how much hard drive space would be required for VAIL-

Plant Database. It is recommended to store out-with the database to attain good performance from

database. The information below is only a rough guide.

At least 8GB hard drive space



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4 SOFTWARE INSTALLATION

Software installation instructions are provided in the VAIL-Plant Installation Manual Revision

1.3. In this manual, we consider that the software has been successfully installed using the

information provided in the Installation Manual. The installation places one shortcut on the

user’s desktop as well as two menu items in the program menu.

5 SOFTWARE STARTUP

5.1 Startup

The software can be started using either of two methods:

1) The VAIL-Plant Installation shortcut on desktop

Figure 5-1 VAIL-Plant Desktop Shortcut

The desktop shortcut of the VAIL-Plant Installation is the easiest method to start VAIL-

Plant. Double click the icon highlighted in the above screenshot to start the application.

2) The VAIL-Plant Installation shortcut from the program menu

Click the Start icon and select “All Programs”. Go to the folder named “VAIL-Plant”. On

clicking this folder, an icon of VAIL-Plant application shall appear. Click once on the

icon in order to start the application. The figure below illustrates the shortcut icon for

Windows 7.



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Figure 5-2 Program Menu VAIL-Plant Shortcut

5.1.1 User Login

Figure 5-3 Login screen

Every time the user starts VAIL-Plant, a login screen as shown in the above screenshot will be

displayed. First, user must select the appropriate system name from the “System” dropdown as



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guided by administrator. A valid username and password will be required for login. These will

be provided by the administrator.

5.2 Dashboard

Successful login gives way to the VAIL-Plant® dashboard as shown in the figure below. All

these modules are also located on a ribbon and are accessible from every screen of VAIL-

Plant®. User shall be able to click on only limited icons, based on the settings configured by the

administrator for the assigned user group. The rest of the icons shall be inactive. On the

dashboard, an active module icon is one whose border turns black in color when you place your

mouse over it. Clicking the PEMS icon opens up the PEMS module.

Figure 5-4 Dashboard



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6 VAIL-Plant Interface

The purpose of this section is to provide the user familiarity with the user interface of the

software, its usability, its operation and its capability. The elements of the user interface

described in this section are common to most modules. These elements are:

1) Button Ribbon

2) Outlook Bar

3) User Details

4) Navigation Tree

5) Views Navigator

Figure 6-1 VAIL-Plant Main screen

At the top left corner of main application interface is the name ‘VAIL-Plant’. A ribbon is at the

top containing different modules of VAIL-Plant. This ribbon is fixed and access of its buttons is



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based on user’s access / permissions level. When user clicks on any of the modules from the

Ribbon, that module loads. The bottom right corner shows the user login and time details.

6.1 Button Ribbon Functions

Ribbon contains button icons for all the modules of VAIL-Plant each for a different set of

equipment. It also contains the functions of logging off and closing the application. This ribbon

is always accessible from any screen of the application. The button icons on the ribbon are listed

below.

Pressurized Equipment Management System (PEMS)

Structure Integrity Management System (SIMS)

Pressure Safety Valve & relief Valve Management System (PSVMS)

Lifting Equipment Management System (LEMS)

Pipeline Integrity Management System (PIMS)

Miscellaneous Equipment Management System (MEMS)

Civil Inspection Management System (CIMS)

Electrical, Instrumental and Rotary Management System (EIRMS)

Hull Integrity Management System (HIMS)

Wellhead Integrity Management System (WHIMS)

Cathodic Protection Condition Evaluation System (CPMS)

Inspection Scheduling & Management System (ISMS)

Facility Status Integrity Report (FSIR)

Company

Log Off

Close

VAIL-Plant Button Ribbon

Figure 6-2 Button Ribbon



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6.1.1 PEMS (Pressurized Equipment Management System)

PEMS module is accessed via the PEMS icon in the ribbon. PEMS module

contains the information of all pressurized equipments (Pipe, Column, Tanks, Fin Fan Cooler,

Heat Exchanger, Heater, Reactor, Vessels etc.), so it is named as Pressurized Equipment

Management System.

6.1.2 COMPANY Button

COMPANY setting form is accessed via the Company icon in the ribbon. Company form

provides the information of a company which will use VAIL-Plant and administrator can edit or

update this information according to his company profile.

6.1.3 LOG OFF Button

User can log-off application by clicking on the Log-Off button icon in the ribbon. Clicking this

button will return user to the login screen.

6.1.4 CLOSE Button

VAIL-Plant can be closed by clicking on the CLOSE button icon in the ribbon.

6.2 User Details

The bottom right corner shows the username with which the user logged into the software. This username is based on their roles and responsibilities. It also shows the login time, Server name and database time. It has a link to change the password.

Figure 6-3 User Details



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6.3 Outlook Bar

The Outlook bar is situated in the left side of the interface. The purpose of

this outlook bar is to provide the different data views of record navigation

i.e. Form View, List View, Report View and User List View to the user.

Providing different data views to the user, user can achieve the maximum

level of accessibility, fastest level of search ability and effective level of

report ability of records. Outlook bar has the following data views and each

view has been described in this section:-

a) Form View (default view)

b) List View

c) Report View

d) User List View

e) Reference Documents

f) SAP Interface

Figure 6-4 The Outlook Bar



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6.4 Navigation Tree

The Navigation Tree is situated just right to the Outlook Bar. The

Upper tree shows the Normal records and the lower tree shows the

Pending records.

Normal records are basically approved records, approved by those

groups which have the rights of review and approve of newly added

or modified equipments i.e. Engineers groups, Managers groups.

Pending records are basically newly added or modified records, by

those groups which have the rights only of write, read & execute and

modify but not of review and approve i.e. inspector, surveyor, data

entry operators etc.

When a record is inserted by inspector or data entry operator it goes

in the pending records tree (Lower tree). Inserted record will not go in

the normal tree records until and unless manager or engineer will

review and approve it.

When a record is modified, it goes in the pending records. But it also

remains in the normal records. In this case, normal records tree keeps

the old information of this modified record and pending records tree

keeps the updated information of this modified record.

A modified record will not overwrite the normal tree record until the

manager or engineer shall review and approve it. After approval,

pending records tree will not show this modified record. The

navigation tree is the primary method to navigate through the data

records. VAIL-Plant® Navigation tree hierarchy is organized in four

ways:-

Figure 6-5 Navigation Tree



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Company-Area-Train-Plant-Corrosion Loop-Equipment-Component

Company-Area-Train-Equipment Type-Equipment-Component

Company-Area-Train-HSECES Group–HSECES Sub Group-Equipment-Component

Company-Area-Train-Corrosion Loop-Equipment-Component

These are described below as the four temporary nodes. Both Normal tree and Pending tree show

the same hierarchy as outlined below.

Level 1: Company Node

The root node is a company node. Company node shows the company name as defined by

company’s administrator. Single click filters the forms records according to the company and

double click or click on the plus sign (collapse icon), navigates down the navigation tree.

Level 2: Area Node

The level 2 node is the area node. Area node shows the area name within a company name as

defined by company’s administrator. Single click filters the forms records according to the

company’s area and double click or click on the plus sign (collapse icon), navigates down the

navigation tree.

Level 3: Train Node

The level 3 node is the Train node. Train node shows the total trains within an area name as

defined by company’s administrator. Single click filters the forms records according to the Train

number and double click or click on the plus sign (collapse icon), navigates down the navigation

tree.

Level 4: Temporary Nodes (Plant, Equipment Type, HSECES, Corrosion Loop)

This level contains four temporary nodes as listed below:

Level 4A: Plant node

Temporary node Plant shows the total plants within a Train. It groups all the equipments in the

Company according to the plant to which they belong. It contains a sub level in the form of

Corrosion Loop. Every plant node groups Corrosion Loops according to the plant they belong to.

Further, every Corrosion Loop groups equipments according to the Corrosion Loop they belong



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to. No filter takes place by single click on this node. Double click or click on the plus sign

(collapse icon), navigates down the navigation tree.

Level 4B: Equipment type node

Temporary node Equipment Type shows all the equipment types within a Train. For instance, fin

fan cooler, pipe etc. It groups all the equipments in the Company according to the type of

equipment to which they belong.

Double click or click on the plus sign (collapse icon), navigates down the navigation tree.

Level 4C: HSECES node (Health, Safety and Environmental Critical Equipment Systems)

This node shows those assets which are critical to health, safety and environment. It groups

equipments according to the HSECES group and HSECES sub group under which they fall.

Double click or click on the plus sign (collapse icon), navigates down the navigation tree.

Level 4D: Corrosion loop node

Temporary node Corrosion loop shows the total corrosion loops within a Train. It groups all the

equipments in the Company according to the corrosion loop to which they belong. Double click

or click on the plus sign (collapse icon), navigates down the navigation tree.

Level 5: Equipment Node

Equipment node shows the total Equipments within a temporary node classified according to the

node under which it falls. For example, for the Plant temporary node, the Equipment level is

classified according to the plants under which the equipment fall. For the HSECES temporary

node, the equipment is classified according to the HSECES groups and sub groups under which

they fall. Single click filters the forms records according to the Equipment and double click or

click on the plus sign (collapse icon), navigates down the navigation tree. It contains all the

components which belong to the equipment along with their traffic colors.

Level 6: Component Node

Component node shows the total components in the equipment. Single click filters the form and

shows overall data of one component. This node also shows the traffic light color based on either

risk ranking or remaining life of a component, as set by the administrator.



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6.4.1 Applying Tree Filter

The Tree Filter feature is used to filter records by selecting required criteria.

Figure 6-6 Tree Filter

On clicking the ‘Apply Tree Filter’ button at the top of the Navigation Tree, as shown in the

above screenshot, the window as shown below opens up.

Figure 6-7 Applying Tree Filter

Check the boxes against the required Trains, Plants, Equipment types and the damage

mechanisms to apply the filter as required. Click the ‘Apply Filter’ button.

The Filter is applied as shown in the screenshot below. Now the Navigation tree displays only

the Filtered components. The ‘Apply Tree Filter’ button is replaced by the ‘Remove Tree Filter’

button. For example, in the above screenshot, filter is applied to show records under the Plants

“New Power Plant”, “Utility Platform” falling under the train “Utilities”.



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6.5 Views Navigator

The view navigator is situated just right of the Navigation Tree. User can select a view by just

clicking the view button in the Outlook Bar and this selected view appears in the views

navigator. The default view is the Form View when a module loads. There are following views

shown by views navigator, as described already in the section describing Outlook Bar.

a) Form View (default view)

b) List View

c) Report View

d) User List View

e) Reference Documents

f) SAP Interface

Figure 6-8 Views Navigator



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7 PEMS Module (Pressurized Equipment Management System)

7.1 PEMS Form View

This is the default view when the PEMS module is started.

7.1.1 Form View Toolbar

Figure 7-1 Form View Toolbar

The Form View toolbar is situated at the top-right corner of the Form View. The toolbar contains

the following buttons and features:-

1. Trends – Displays reports for Number of Leaks, Defects, Corrosion Rate etc. in each

plant. These are elaborated in section ‘Reporting’.

2. Drawings – Enables adding and viewing of drawings and documents to assets.

3. Engineering Data – Read only information about the engineering parameters of

components.

4. New – Enables adding of a new component.

5. Save – Enables saving the addition or update of a component.

6. Edit – Enables updating the information about a component.

7. Delete – Enables deleting a component.

8. Drop – Enables dropping any addition of newly added component or changes made to

an existing component.

9. Calculate – Enables viewing of important calculations such as RBI results, Inspection

interval, Next inspection date, Risk, Metal loss, Corrosion rate and Remaining life.

10. KPI Data – KPI (Key Performance Indicator) module allows entering and graphically

displaying standard industry metrics such as Mean Time Between Failure, Equipment

Availability etc as well as user defined metrics unique to the organization. It alerts

company personnel when these metrics fall outside the established limits.

11. Review/Approve - Enables Reviewer or Approver to do the needful with the record.



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12. Info – Enables viewing information about the record such as who recorded, modified,

reviewed and approved it.

13. Send Screenshot – Enables drafting an email with the print screen of the current

screen as an attachment. When you click on the “Camera Icon”, a new Email window

of MS Outlook will open with subject name as “Screen shot” and attached JPG file as

“FileName.jpg”. You only need to enter the recipient email address and send the

screen shot.

14. Advanced Search – Enables full text and wild card search of any equipment or

component.

7.1.1.1 Trends

Trends form is accessed via the Trends icon on the toolbar. Trends button allows the user to see

graphical representation of failures, leaks, defects, replacements, inspection history (remaining

thickness, corrosion rate, remaining life, anomalies etc.) and risk ranking that comes from Risk

Based Inspection.

Train filter can be applied by selecting trains in the upper left list box and Plant filter can be

applied by selecting plants in the below left list box. Plants are filtered based on Trains or groups

of Trains.

There is a ‘Screenshot’ button to send a screenshot of the current screen view by email.

The graphical information can be viewed in the forms of list by clicking on List view button.

User can move Chart View to List View or vice versa. When the List View is accessed, the

‘Export to excel button becomes active and user has the option to export the results to an excel

file and save it to hard drive. This is shown in the below figures.

Figure 7-2 Left: Trends Chart View; Right: Trends List View



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The steps to export to excel are elaborated below:

1. Click on the ‘List View’ button. The ‘Export to Excel’ button shall become active. Click

this button.

2. First you shall be prompted by the message below. Click ‘Yes’.

Figure 7-3 Export to excel – first dialogue box

3. Then, the dialogue box shown below shall appear and you can browse to any folder, enter

a name for the file and click the ‘Save’ button.

Figure 7-4 Export to Excel - Saving the file



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7.1.1.1.1 Leaks trend

Through this screen, you can see the history of leaks that have taken place in the past. Date filter

is available to see the number of leaks between two dates.

Specify appropriate dates in the fields ‘Date From’ and ‘Date To’ and then click on the ‘Apply

Filter’ button. A chart is displayed, as shown in screenshot below, showing the number of leaks

per plant. Clicking on a particular bar graph corresponding to a plant displays a new window

containing a list view of all the details of those tags which belong to that plant. The total number

of tags is shown at the top of the new window.

Figure 7-5 Leaks Trend – Chart View

The display is ‘Chart View’ by default. You can see the data in a list by clicking on the ‘List

View’ button at the upper right corner of the screen. This is shown in the below screenshot.



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Figure 7-6 Leaks Trend - List View

7.1.1.1.2 Defects Trend

Figure 7-7 Defects Trend



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Through this screen, you can see the history of defects that have taken place in the past. Date

filter is available to see the number of defects between two dates.

Select a specific failure code (defined by admin) to filter according to failure reason or ‘All’ to

see all the defects. Specify appropriate dates in the fields ‘Date From’ and ‘Date To’ and then

click on the ‘Apply Filter’ button. A chart is displayed, as shown in screenshot above, showing

the number of defects per plant. Clicking on a particular bar graph corresponding to a plant

displays a new window containing a list view of all the details of those tags which belong to that

plant. The total number of tags is shown at the top of the new window.

7.1.1.1.3 Risk Trend

Through this screen, you can see the High, Medium High, Medium and Low risk items or

equipments that are covered in Risk Based Inspection.

Click on the Risk dropdown to select the risk as one of the following: ‘Low’, ‘Medium’, ‘High’,

‘Medium High’ or ‘High’. Click on the ‘Apply Filter’ button. A chart appears, as shown in

screenshot below, showing the plants having the risk as selected by you in the dropdown. It

shows the number of components per plant having the selected risk.

Clicking on a particular bar graph corresponding to a plant displays a new window containing a

list view of all the details of those tags which belong to that plant. The total number of tags is

shown at the top of the new window.



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Figure 7-8 Risk Trend

7.1.1.1.4 Replacements Trend

Through this screen, you can see the number of equipments that have been replaced till date.

Select a replacement code from the dropdown or select ‘All’ to see all replacements. Select

appropriate dates in the ‘Date From’ and ‘Date To’ fields. Click the ‘Apply Filter’ button.

A chart is displayed, as shown in screenshot below, showing the number of replacements per

plant. Clicking on a particular bar graph corresponding to a plant displays a new window

containing a list view of all the details of those tags which belong to that plant. The total number

of tags is shown at the top of the new window.



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Figure 7-9 Replacements Trend

7.1.1.1.5 Corrosion Rate Trend

Through this screen, you can see the graphical view of corrosion rate history by giving

appropriate value in the dropdown filter.

Click on the ‘Enter Corrosion’ dropdown to select one of ‘Equal to’, ’Less than’, ‘Greater than’,

‘Between’, ‘Less than equal to’ or ‘Greater than equal to’. Enter the required corrosion rate in

mils/year. For example: to view all plants with a corrosion rate that is less than 10 mils/year,

Select the option ‘Less than’ from the dropdown and then type ‘10’ in the textbox. Click on the

‘Apply Filter’ button. A chart appears, as shown in screenshot below, showing the plants having

the rate selected by you in the dropdown. It shows the number of components per plant having

the specified corrosion rate.






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Figure 7-10 Corrosion Rate Trend

7.1.1.1.6 Metal Loss Trend

Through this screen, you can see the graphical view of metal loss history by giving appropriate

value in the dropdown filter.

Click on the ‘Metal Loss’ dropdown to select one of ‘Equal to’, ’Less than’, ‘Greater than’,

‘Between’, ‘Less than equal to’ or ‘Greater than equal to’. Enter the required loss in mm. For

example: to view all plants with metal loss less than 2 mm, select the option ‘Less than’ from the

dropdown and then type ‘2’ in the textbox. Click on the ‘Apply Filter’ button. A chart appears, as

shown in screenshot below, showing the plants having the loss as selected by you in the

dropdown. It shows the number of components per plant having the specified metal loss.






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Figure 7-11 Metal Loss Trend

7.1.1.1.7 Remnant Life Trend

Through this screen, you can see the graphical view of the remaining useful life of equipment by

giving appropriate value in the dropdown filter.

Click on the ‘Remnant Life’ dropdown to select one of ‘Equal to’, ’Less than’, ‘Greater than’,

‘Between’, ‘Less than equal to’ or ‘Greater than equal to’. Enter the required value of remaining

life in years. For example, to view all plants with remaining life less than 10 years, select the

option ‘Less than’ from the dropdown and then type ‘10’ in the textbox. Click on the ‘Apply

Filter’ button. A chart appears as shown in the figure below. It shows the number of components

per plant having the specified remnant life.






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Figure 7-12 Remnant Life Trend

7.1.1.1.8 Anomalies Trend

Through this screen, you can see the graphical view of the remaining useful life of equipment by

giving appropriate value in the dropdown filter.

Select an anomaly code to see results for a specific anomaly or ‘All’ to see all anomalies. Select

the appropriate dates in the ‘Date From’ and ‘Date To’ fields. Click on the ‘Apply Filter’ button.

A chart appears as shown in the figure below. It shows the number of anomalies that occurred in

each plant in the specified duration.






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Figure 7-13 Anomalies Trend

7.1.1.2 Drawings

Drawings form accessed via the Drawings icon on the toolbar. Drawings form allows user to

view and add multiple drawings under multiple categories (i.e. Sample Sketch, Isometrics, GA

drawings, Corrosion circuit drawings etc.) for each record.

Figure 7-14 Drawing icon on Form View Toolbar

a) View drawings

Drawings can be viewed by selecting “View drawings” tab. Multiples drawing files will be

displayed according to the selected drawing category. A drawing viewer in the right side displays

the selected drawing or file. User can view this selected file in full window by just clicking on

the “View in Separate Window” button.



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Figure 7-15 View Drawings

b) Remove Drawings

Navigate to the component for which you want to remove a drawing. Click on the ‘Drawing’

button on the Form View Toolbar. Click the ‘View Drawings’ tab. Click the drawing you want to

remove to select it. Click the Delete button. You shall be prompted to confirm if you want to

remove the drawing. Then a message shall appear to report that the drawing was successfully

deleted.

c) Add drawings

Drawings can be added by selecting “Add drawings” tab. By clicking on the “Browse” button

user can select the drawing or file to be added. You can only upload files in PDF format.

Multiples drawing files can be added according to the selected drawing category. A drawing

viewer in the right side displays the added drawing or file. “Add” button is used to save drawing

or file.



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Figure 7-16 Add Drawings

7.1.1.3 Engineering Data Engineering Data form is accessed via the Engineering Data icon on the toolbar and is as shown

in the below screenshot. Engineering Data form allows user to view Engineering data and

Operational data of an equipment or equipment tag, for read only purpose. User can find the

main interface of Engineering Data in “EnggData” tab of Form View. The “Engineering Data”

icon on the toolbar provide a high availability and effective interface for Engineering Data to aid

calculation and validation from anywhere in the Form View.



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Figure 7-17 Engineering Data Dialogue box

7.1.1.4 New button

New button accessed via “New” button icon on the toolbar. New button allows user to add new

record or new equipment in the database. Access of this button is only for those users, who have

the permission of insert or writing new record. All read only fields will be editable after click on

this button.

Figure 7-18 New Icon on toolbar

When a user clicks on the new button, a dialogue box as shown next will appear:



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Figure 7-19 Adding new Asset from Form or Excel Sheet

Option “Adding from Entry Form”: If the user clicks on the ‘Add New Record from Entry Form’

button, a dialogue box will appear as shown below. Now the user has two choices to enter the

new record. This is described next.

Figure 7-20 Adding new Asset – Do you want to copy duplicate data

a) Copy duplicate data

If he clicks “Yes” then he will be able to copy all data of current record into inserted record

except equipment identity number. It saves time taken in entering data especially when inserted

record has the same hierarchy as the current record.



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Figure 7-21 Adding new asset - copying duplicate data

b) Start as blank fields

If he clicks “No” then he will be able to enter all new information of inserted record. In this case

at least hierarchy fields should be completed i.e. Company Name, Area Name, Train Number,

Plant Number, Corrosion Loop, Equipment Tag, Component Tag, Equipment Type etc. Other

information he can fill or edit later.



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Figure 7-22 Adding new asset - starting with blank fields

Option “Loading From Excel”: If user selects this option, he may upload one or multiple records

at one time. For this, the record/s must be in the correct template in an excel file which is

provided in software DVD (with name “PEMS Master Data”). The application shall verify the

validation of the template as well as the records before uploading them.

Once this option is selected, a dialog box opens as shown below shall appear allowing user to

select the excel file in the valid template from users hard disk.



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Figure 7-23 Selecting excel file in valid template

On selecting the file, the below screen shall appear if the template is valid.

Figure 7-24 Excel File loading

Once the records are loaded, the below screen shall appear. This screen asks user to initiate

verification of the loaded records by the application.



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Figure 7-25 Verifying loaded records

User must click the button “Verify Records before Uploading”. On doing this, the below screen

shall appear if the records are valid. This screen tells user that the data is verified.

Figure 7-26 Data verified

On clicking “OK”, the below screen shall appear.



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Figure 7-27 Uploading records after validation

User must click the “Upload to VAIL-Plant”. On doing this the application proceeds to load the

records. A dialog box indicating the status of the upload is shown to user such as “Successfully

loaded”. These records shall appear in the application as though they were manually uploaded.

7.1.1.5 Save Button

Save function is accessed via “Save” button icon on the toolbar. Save button allows user to save

new or edited records in the database. Access of this button is only for those users, who have the

permission to insert and edit.

By default all fields are read only and color is gray. When a user inserts or edits a record by

using “NEW” or “EDIT” button, all fields become editable and their color becomes white. After

clicking on the “SAVE” button, all fields go to their default mode.

Note: When SAVE button is enabled, at that time NEW, EDIT and DELETE buttons are

disabled and vice versa.



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The Save button is illustrated below.

Figure 7-28 Save icon on toolbar

7.1.1.6 Edit Button

Edit function is accessed via the “Edit” button icon on the toolbar. Edit button allows user to edit

current record. Access of this button is only for those users, who have the permission to modify.

By default all fields are read only and their color is gray. When a user edits a record by using

“EDIT” button, all fields become editable and their color becomes white. After clicking on the

“SAVE” button all fields go to their default mode.

Figure 7-29 Edit icon on toolbar

7.1.1.7 Delete Button

Delete function is accessed via the “Delete” button icon on the toolbar. Delete button allows user

to delete current record. Access of this button is only for those users, who have the permission to

delete records.

Figure 7-30 Delete icon on toolbar

7.1.1.8 Drop Button

DROP function is accessed via “Drop” button icon on the toolbar. Drop button allows user to

drop or withdraw changes made through INSERT or EDIT command performed by the user on

current record. This feature is available only for that purpose, if the user changes his mind.

Figure 7-31 Drop icon on toolbar



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7.1.1.9 Calculate Button

CALCULATE function is accessed via the “Calculate” button icon on the toolbar. Calculate

button allows user to calculate RBI results, Inspection interval, Next inspection date, Risk, Metal

loss, Corrosion rate and Remaining life.

Figure 7-32 Calculate icon on toolbar

7.1.1.10 KPI Calculator

KPI (Key Performance Indicators) module is accessed via the “KPI” button icon on the toolbar.

KPI module has the following functionalities:

The system has capable to incorporate standard industry metrics such as Mean Time

between Failure (MTBF), Mean Time between Events, Equipment Reliability, Equipment

Availability as well as is flexible to allow user defined metrics based on the system’s data

and other external data sources.

Support metrics involving incidents and lost production.

Enterprise-wide metrics for maintenance, reliability, safety, environmental, health, asset

and financial problems.

Support and display a multilevel performance scoreboard.

Support the building of Key Performance Indicators (KPI) and their display.

Support the graphical display of all metrics.

Alert company personnel when KPIs fall outside of established limits.

Provide configured KPIs for the company.



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KPI Form

Figure 7-33 KPI Form

7.1.1.11 Review Button

REVIEW function is accessed via the “Review” button icon on the toolbar. Review button

allows user to review pending records in the lower navigation tree. Review button will be

accessible only for those groups who have the rights of review i.e. Engineer group.

7.1.1.12 Approve Button

APPROVE function is accessed via the “Approve” button icon on the toolbar. Approve button

allows user to approve pending records in the lower navigation tree. Approve button will be

accessible only for those groups which have the rights of approval i.e. Manager group.

7.1.1.13 Record Info Button

INFO function is accessed via the “Info” button icon on the toolbar. Info button allows user to

see the update status of the current record i.e. who entered, modified, review and approved it.



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Record Information Form

Figure 7-34 Record Info form

7.1.1.14 Advanced Search

Click on the “>>” button on the Form View Toolbar and then click on the ‘Advanced Search’

button. On clicking, all fields shall become blank, all filters shall be removed, trees will be

collapsed and some fields shall change their color to Salmon color. Search is allowed only for

the Salmon fields. This button allows user to do two types of search: Full Text and Wild card.

Figure 7-35 Form View Toolbar – Advanced Search



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Note: VAIL-Plant® has the capability to automatically identify whether performed search is full

text or wild card based on asterisk (*). If the search field includes text without asterisk, it

considers that the performed search is Full text. If the search field includes text with asterisk, it

considers that the performed search is Wild card.

a) Full Text Search

Full text search allows you to match the whole field to search. If the full text will match any

existing data, results will be shown, otherwise not. For full text search, you shall need to write

full text in the Salmon fields without asterisk (*) or select the required value from the

dropdowns. Click on ‘Clear All’ if you want to clear the text you entered or selected and to reset

the search textboxes. You may search based on any one Salmon field or multiple ones.

Click on search. If the search result contains more than one record, a list box shall appear with a

list of matching records. Double click on the required record to view it. In the below example,

only one result is returned and hence the record opens in the View Navigator.

Performed Full Text Search

Result of Full Text Search



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Figures 7-36 Advanced Full Text Search

b) Wild Card Search

Wild card search allows you to match any part of the field to search. For Wild card search, you

can write any string or character in Salmon fields and suffix it with an asterisk (*). Click on the

‘Search’ button. All the matching records shall appear in a list box. Double click on the required

record to view it.

Performed Wild Card Search



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Result of Wild Card Search

Figures 7-37 Advanced Wild Card Search

7.1.2 Form View “Search Combo box”

The Search Combo box is situated upper right corner in the Form View. With the help of this

combo box user can directly jump to desired record or equipment. It supports full text search and

shows all Equipment tags or Functional locations those are exist in the plant hierarchy.

a) Selecting an equipment by drop down property

User can directly go to the desired record or equipment by Combo box drop down property.

When user types a part of the Equipment Tag number, all the records matching that text appear

in the dropdown box. User can select the desired record.



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Result of Search

Figure 7-38 Search Combo Box - Selecting equipment from dropdown



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b) Selecting an equipment by auto suggest property

User can also directly go to the desired record or equipment by Combo box auto suggests

property. When user begins to type the Equipment Tag number, the auto-suggest feature prompts

the remaining part of the tag number, making it easier to search for a given record.

Result of Search

Figure 7-39 Search Combo box - Auto suggest property



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c) Selecting an equipment through wild card search

User can search for any equipment by typing the first few letters (minimum first letter)

followed by an asterisk in the search combo box as shown in the screenshot below. On

clicking the ‘Search’ button, a list shall appear with all the equipment starting with those

letters. On double clicking the required equipment from the list, the record for that

equipment gets loaded to the application.

Result of Search

Figure 7-40 Search Combo box - Wild card property



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7.1.3 Form View Record Navigator

Record Navigator is just situated middle bottom in Form View. Record Navigator shows the

current record and the total number of records. With navigation buttons user can go to the first

record, last record, previous record and next record.

Figure 7-41 Record Navigator

Total Main Tags Textbox

Total Main Tags Textbox is situated just right to the navigation buttons tool. Basically

equipment is a collection of different components and this textbox displays a count of all the

equipments defined in the system.

Total Tags Textbox

Total Tags Textbox is the total number of records or we can say total number of components

defined in the current level selected in the Navigation Tree. Component is a unique record in the

database. This textbox also shows the current record out of total records.

First Button

By clicking on this button user can directly go to the first record.

Figure 7-42 Record Navigator - First button

Last Button

By clicking on this button user can directly go to the last record.

Figure 7-43 Record Navigator - Last button



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Previous Button

By clicking on this button user can go to the previous record.

Figure 7-44 Record Navigator - Previous button

Next Button

By clicking on this button user can go to the next record.

Figure 7-45 Record Navigator - Next button

7.1.4 Form View Tabs

Form View tabs become visible/ invisible by clicking on the Form View button in the Outlook

bar. That’s why one tab is visible at a time in the Outlook bar. The purpose of these tabs is to

segregate the data for each record.

7.1.4.1 Equipment Main Data

Form View Equipment Main Data portion is situated in the upper half of Form View. It remains

same on selection of any Form View tab from Form View’s button in the Outlook bar. It shows

the hierarchy data and risk of a current equipment or record.



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Figure 7-46 Equipment Main Data

7.1.4.2 Engineering Data Tab

Engineering Data Tab is accessed via the “Engg Data” Form View button in the Outlook bar.

Engineering Data tab shows the Engineering data and operational data of the current equipment

or record.

Figure 7-47 Engineering Data



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7.1.4.3 Third Party RBI Results Tab

This tab is accessed via the “Third Party RBI Results” Form View button in the Outlook bar.

This tab is used to link any third party software for RBI owned by the client into VAIL-Plant.

For example if client also has API-RBI software then results from this software can be interfaced

into VAIL-Plant application through this tab. In the below screenshot, API-RBI Results tab

shows the API-RBI results of the current equipment or record.

Figure 7-48 API -RBI Results Tab

7.1.4.4 Velosi RBI Tab

Velosi RBI Tab is accessed via the “Velosi RBI” Form View button in the Outlook bar. Velosi

RBI tab shows the possible damage mechanisms, facilitates allocating these damage mechanisms

to individual tags, determination of PoF, CoF and risks values, Calculation of Interval factor,

Inspection interval and Next inspection date etc.

The RBI Assessment Process is outlined in the figure below.



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Figure 7-49 RBI Assessment Process

a) How to add failure modes and POF, CoF for a Component?

Failure modes can be added to components by the procedure enlisted below.

1) Navigate to the component for which you want to add/edit the failure mode. For a newly

added component, navigate to the component in the ‘Pending Records’ area.

2) Click on the ‘Velosi RBI’ tab within the ‘Form View’ on the Outlook Bar.

3) Click on the ‘Add’ button on the toolbar of the “Allocate Damage Mechanisms’ tab as

shown in the screenshot below.

4) Select the first relevant failure mode from the dropdown against the text ‘Damage

Mechanism’. User may select one or more damage causes from a list box. This selection

will enable the right focus in the estimated corrosion rate models in the next screen.

5) Click on the dropdown for Probability Assessment and Consequence Assessment one by

one, and select whether the selected damage mechanism’s probability/ consequence of

occurrence are Potential or Insignificant. This is used for the initial screening of damage

Allocate Damage Mechanisms •Every component is allocated relevant damage mechanisms.

PoF Assessment

•The Probability of Failure is assessed based on a questionnaire which is specific to each damage mechanism. A PoF category of 1 to 5 is assigned.

CoF Assessment

•The CoF is assessed based on a questionnaire for each of the consequence categories: business, safety, environment and capital.

InspectionEffectiveness

•An Inspection Effectiveness score and rating are assigned to each component on the basis of a questionnaire.

Assess Risk•The Risk category is calculated for each component by looking up the PoF and maximum CoF on the Risk Matrix.

Inspection Interval

•The Inspection Interval is calculated for each equipment. The highest risk from among the component risks is assigned as the equipment risk. The equipment risk, inspection effectiveness, historical corrosion rates and the remnant life are taken into account to arrive at the Next Inspection Date.



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mechanisms. Only those damage mechanisms for which both the Probability and

Consequence are Potential are considered for the Risk assessment process. In case user

wants to override this behavior, he/she may select either Yes or No in the ‘Proposed’

dropdown. If user selects Yes or No in this dropdown, the damage mechanism shall be

considered or rejected respectively for Risk Assessment regardless of its Probability and

Consequence values.

Figure 7-50 Adding a New Failure Mode

6) Click on the Velosi RBI tab and the default selected tab shall be Probability/

Susceptibility Assessment. Navigate to the damage mechanism for which you wish to

record the PoF and CoF values using the record navigator shown in the screen below.

Specific to the selected damage mechanism, a questionnaire shall be loaded. On

selecting the appropriate option, the PoF category shall be determined and displayed

on the screen.



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Figure 7-51 Assigning PoF to a damage mechanism

7) Click on the Consequence Assessment tab highlighted in the screenshot below. The

default sub tab selected shall be Business. Select the analysis level you choose to

apply for the CoF determination from Levels 1, 2 and 3 with Level 3 being the most

detailed and Level 1 being the least detailed. Specific to the selected level, a set of

fields shall be displayed. On selecting/ entering the appropriate data, the CoF value

for the business category shall be determined and displayed on the screen. The

screens for each of the three levels of business consequence assessment are shown

below.



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Figure 7-52 Business Level 1, 2 and 3 Consequence analysis

8) Within Velosi RBI tab -> Consequence assessment tab, click on the Safety sub tab

highlighted in the screenshot below. Select the analysis level you choose to apply for

the CoF determination from Levels 1, 2 and 3 with Level 3 being the most detailed



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and Level 1 being the least detailed. Specific to the selected level, a set of fields shall

be displayed. On selecting/ entering the appropriate data, the CoF value for the safety

category shall be determined and displayed on the screen. The screens for each of the

three levels of safety consequence assessment are shown below.

Figure 7-53 Safety Level 1, 2 and 3 Consequence analysis



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9) Within Velosi RBI tab -> Consequence assessment tab, click on the Environment sub

tab highlighted in the screenshot below. Select the analysis level you choose to apply

for the CoF determination from Levels 1, 2 and 3 with Level 3 being the most

detailed and Level 1 being the least detailed. Specific to the selected level, a set of

fields shall be displayed. On selecting/ entering the appropriate data, the CoF value

for the environment category shall be determined and displayed on the screen. The

screens for each of the three levels of environment consequence assessment are

shown below.



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Figure 7-54 Environment Level 1, 2 and 3 Consequence analysis

10) Within Velosi RBI tab -> Consequence assessment tab, click on the Capital sub tab

highlighted in the screenshot below. On selecting the appropriate option, the CoF

value for the Capital category shall be determined and displayed on the screen.

Figure 7-55 Capital Consequence Assessment



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11) Within Velosi RBI tab, click on the ‘Inspection Effectiveness’ Tab highlighted in the

screenshot below. Select the appropriate answer for each of the three questions by

clicking on the radio button against them. On doing so, the Inspection Effectiveness

in terms of the Score and Rating shall be calculated and displayed.

Figure 7-56 Inspection Effectiveness Score and Rating

12) Click on the “Save” button. This will save all the data regarding PoF, CoF and

inspection effectiveness for the selected damage mechanism.

13) Within Velosi RBI tab, click the ‘Risk Matrix’ tab as shown highlighted in the

screenshot below. To the left, shall be displayed a summary of the PoF, CoF and

inspection effectiveness for the selected damage mechanism. To the right, the Risk

Matrix shall be displayed, highlighting the color code of the risk associated with the

current failure mode of the selected component. It is the intersection of the probability

class and criticality class as shown in the below screenshot. You have the option of

selecting the ‘Screenshot’ button at the bottom of the dialogue box to draft an email

with an attached print screen. This Risk Matrix is configurable from the Control Panel

accessible only to the administrator user.



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Figure 7-57 Risk Matrix

14) Alongside the Velosi RBI tab, click the ‘Risk Summary’ tab as shown highlighted in

the screenshot below, to view a tabulated summary of the risk of the component. It

enlists the PoF, CoF (business, safety, environment and capital), calculated value of

CoF maximum and risk category for each failure mode allocated to the component.

Further based on the maximum values of PoF and CoF maximum from the damage

mechanisms, the PoF overall, CoF overall and the Risk overall for the component are

displayed.

Figure 7-58 Risk Summary



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15) Alongside the ‘Risk Summary’ tab, click the ‘RBI Results’ tab as shown highlighted

in the screenshot below, to view the results of the Risk assessment of the component.

On this screen, the user may select the type of corrosion rate to be used in the

calculation of the Next Inspection Date from among the options of : Design,

Measured, Expert or Estimated. The Design Corrosion rate is the corrosion allowance

set during the design phase of the component. The measured corrosion rate is the

actually measured rate during the most recent inspection. The Expert Corrosion rate is

an input from the user based on human expertise. The Estimated Corrosion rate is

determined from the corrosion rate models on the screen for PoF determination.

16) Select the desired type of corrosion rate and click the ‘Calculate’ icon on the Form

View Toolbar. The Inspection Plan Factor, Inspection Duration, Next Inspection Date

and coverage shall be calculated and displayed as shown in the screenshot below. The

‘Risk Overall’ section gets populated with the calculations for Overall PoF, Overall

CoF and Overall Risk Ranking for the component which is the combination of these

factors for all the failure modes associated with the component. There are links to

access the Risk Matrix, Inspection Planning screen and RBI report.

Figure 7-59 RBI Results

17) To determine the estimated corrosion rate for each failure mode, navigate to the

VELOSI RBI tab ->Probability/ Susceptibility Assessment tab, navigate to the



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required failure mode and click on ‘ECR Model’ button as shown highlighted in the

screenshot below. There are built-in models for calculating the estimated corrosion

rates and the susceptibility levels. This is shown for SCC in the figure below.

Figure 7-60 Velosi RBI - Estimated Corrosion Rate Models for damage mechanisms

This button is specific to the failure mode you have chosen. The screenshot below

shows the dialog box and options available with the selected failure mode of ‘Internal

Corrosion’. It includes various models to estimate the corrosion rate. Among other

models, it has the CO2/H2S Corrosion model (focused in the screenshot below)

which calculates the Corrosion rate based on the user inputs of the operating

temperature, pressure, partial pressure of CO2 and the applicable corrections. The

Water Injection Corrosion Model includes four types of models to arrive at the

Corrosion Rate. Depending on the tab chosen by the user, the corresponding

Corrosion rate is updated in the ‘Estimated Corrosion Rate’ field of the ‘Velosi-RBI’

tab.



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Figure 7-61 CO2 and H2S Corrosion Model for Thinning Failure Mode

18) Repeat the steps 1 to 17 to add more failure modes to the component.

b) How to Update Failure Mode information for a Component?

1) Navigate to the required Component using the Tree.

2) Click on the ‘Velosi RBI’ tab within the ‘Form View’ tab.

3) To update damage mechanism information, In the “Allocate damage mechanism” tab,

click on the Edit icon alongside the damage mechanism you wish to edit. In the form that

pops up, update the data and click the Save button.

4) To edit the PoF, CoF, Inspection Effectiveness data, click the ‘Velosi RBI’ tab. Use the

navigation buttons to arrive at the damage mechanism you wish to edit. Make the

required changes to the PoF, CoF, Inspection Effectiveness tabs and click the Save

button.

c) How to Delete Failure Mode information for a Component?



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1) Navigate to the required Component using the Tree.

2) Click on the ‘Velosi RBI’ tab within the ‘Form View’ tab.

3) To delete any information regarding a damage mechanism, it is necessary to delete that

failure mode. In the “Allocate damage mechanism” tab, click on the Delete icon

alongside the damage mechanism you wish to remove. In the form that pops up, select

‘Ok’ to confirm that you wish to delete the damage mechanism.

7.1.4.5 Inspection Plan

Inspection Plan Tab accessed via the “Inspection Plan” Form View’s button in the Outlook bar.

Inspection Plan tab shows the Inspection planning of On-stream and Off- stream, Inspection

Effectiveness, Inspection techniques, Next inspection date and Plant Inspection Routines (PIR)

of the current record.

Figure 7-62 Inspection Plan Tab

7.1.4.6 History Records Tab

History Records Tab accessed via the “History Records” Form View’s button in the Outlook bar.

History Records tab shows the Inspection History, Failure History and Replacement History of

the current record. The default tab is Inspection History tab.

Inspection history tab shows following types of NDT recording:-



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1. VI – Visual Inspection

2. UTG – Ultrasonic Thickness Gauging

3. UTS - Ultrasonic Thickness Scanning

4. RT – Radiographic Testing

5. MPI – Magnetic Particle Inspection

6. DPT – Dye Penetrant Testing

7. AUT – Automated Ultrasonic Testing

8. UTC – UT Chime

9. PT – Pressure Testing

10. HT – Hardness Testing

11. CPT – Cathodic Protection Testing

12. EC – Eddy Current

13. Surface EC – Surface Eddy Current

14. PAI – Phased Array Inspection

15. TOFD – Time of flight Diffraction

16. TGI

17. IRIS - Internal rotary inspection system

18. GT – General Technique

Inspection History



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Figure 7-63 History Records - Inspection history

Failure History

This will come after selection of the Failure Record tab.

Figure 7-64 History Records - Failure history

The “RCA System” button may be used to perform Root Cause Analysis for each failure.



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The screenshots below show the RCA system screens.

Figure 7-65 Root Cause Analysis

Click on the “New” link on the toolbar to initiate a RCA. Each of the tabs on the left panel is

used to go through the RCA process.

1) The ‘Planning’ tab is used for RCA Planning and listing the emergency actions if any.

2) The ‘Team Establishment’ tab is used for listing the RCA team goals and objectives and

selecting the members of the RCA team along with their responsibilities and skills.

3) The ‘Problem Definition’ tab is used for defining the problem, listing the helping data

documents and for creating the action plan for missing data.

4) It contains the “WH” question analysis to define the problem as shown in the screenshot

above.

5) The ‘Interim Containment Action’ tab is used to document the actions to be taken to

contain the problem before the root cause and subsequent action plan can be developed.

6) The ‘Identification and verification of Root Cause’ tab uses the ‘Why Why Analysis’ to

verify the root cause. It is also used to document the preliminary action plan to counter

the root cause.



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7) The ‘Implementation and Validation PCA’ tab is used to identify permanent corrective

actions (PCA) and document the steps to implement and validate the PCA.

8) The ‘Preventive Recurring’ tab is used to proactively plan the prevention of the

recurrence of the failure by regular reviews and addressing similar systems.

9) The ‘Action’ tab is the final tab and is used for managing the implementation of actions

for countering the failure root cause. It tabulates the corrective action name, person

responsible, planned period, how it was verified, by whom it was performed etc.

Replacement History

This will come after selection of the Replacement History tab.

Figure 7-66 History Records - Replacements history

7.1.4.7 Condition Monitoring Tab

Condition Monitoring can be accessed via the “Condition Monitoring” tab in the Form View tab

on the Outlook bar. This tab is used to input data about an asset for vibration, its thermal cycling,

PMI, Fluid analysis, CP System, Weight Loss Coupon and ERP. The Plant Inspection Engineer

is responsible for entering data into the form that appears after clicking this tab.



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The condition monitoring techniques included are:

1. Vibration

2. Thermal cycling

3. PMI

4. Fluid Analysis

5. CP System

6. Weight Loss Coupon

Figure 7-67 Condition Monitoring Tab

7.1.4.8 Inspection Results Tab

Inspection Results Tab is accessed via the “Inspection Results” Form View’s button in the

Outlook bar.

Inspection Results

Inspection Results tab shows the Inspection Results of the current record i.e. Metal Loss,

Corrosion Rate and Remnant Life.



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Figure 7-68 Inspection Results Tab

Code Compliance Check (CC Check)

The screen as shown in below screenshot shall appear. It shows whether the equipment is “Fit for

Service” in red letters at the bottom of the screen. A CC Check determines whether equipment in

its present condition is suitable for its intended use.

Figure 7-69 CC Check tab



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7.2 PEMS LIST VIEW

User can change the user interface from Form View to List View by clicking on List View

button in the Outlook bar.

Figure 7-70 Changing to List View

As soon as user will click on this button, the View navigation portion will change to following

view i.e. List View.

Figure 7-71 List View



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7.2.1 Grid Header

The panel above the grid in which column names are displayed is the grid header. Under each

column user will find respective records.

Figure 7-72 Grid Header

7.2.2 Sorting of Records

Figure 7-73 Sorting of Records

User will notice that whenever he clicks on the column name in the header, an arrow appears.

This arrow indicates the sorting order of the records in the grid by making the selected column as

a reference.

7.2.3 Sorting Upward

Figure 7-74 Sorting Ascending



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Arrow in the upward direction shows that all the records in this selected column are sorted in

ascending order and rest of the columns will have the same records according to the selected

column data.

7.2.4 Sorting Downward

Arrow in the downward direction shows that all the records in this selected column are sorted in

descending order and rest of the columns will have the same records according to selected

column.

Figure 7-75 Sorting Descending

7.2.5 Records Filtering

Records can easily be filtered by selecting the downward arrow present along with each column

in the grid view. A dropdown list appears showing all the possible values in the column. Select a

value to filter only those records which match the selected column value. You can also apply

multiple filters by selecting filtered values on more than one column.



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Figure 7-76 Filtering Records

Figure 7-77 Filtered records

7.2.6 Exporting to Excel

One of the most important features of the List View is the ability to view all records in a list

format and to be able to export it to an excel file on your computer. This enables sharing data

outside the software and a method to perform further analysis and reporting.



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You can filter records as need be and then click the ‘Export button’ at the top of the page.

On filtering, it is possible that the result set extends to more than a single page.

On Clicking on the ‘Export’ button, the list will appear as a worksheet of Excel File which you

can then save to your hard disk.

7.2.7 List View’s Buttons in the Outlook Bar

The tabs under the List View are very similar to those in the Form View. The same data shown

in form format in the Form View is displayed as a list which can be exported to excel. These are

described briefly below.

Figure 7-78 List View Sub Tabs

7.2.7.1 Engineering Data

The same results which were populating in the Form View of Engineering Data in text fields

populate in the grid, in the List View. Initial columns indicate the equipment hierarchy, where as

the rest of the columns shows the equipment engineering and operational data.



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Figure 7-79 Engineering Data Tab

7.2.7.2 Third party RBI Results

The same results which were populating in the form view of Third party RBI Results in text

fields populate in the grid, in the List View. Initial columns indicate the equipment hierarchy,

where as the rest of the columns shows the Third party RBI results.

Figure 7-80 API-RBI Results tab



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7.2.7.3 Velosi RBI

The same results which were populating in the form view of Velosi-RBI Results in text fields


the rest of the columns shows the VELOSI-RBI results.

Figure 7-81 Velosi RBI tab

7.2.7.4 Inspection Plan

The same results which were populating in the form view of Inspection Plan in text fields


the rest of the columns show the details of inspection plans.



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Figure 7-82 Inspection Plan tab

7.2.7.5 Logistics Requirements

Initial columns indicate the equipment hierarchy and the rest of the columns show the complete

details of logistics requirements for executing a scheduled Inspection.

Figure 7-83 Logistic Requirements tab



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7.2.7.6 History Records

This tab lists the Inspection history, failure history and replacement history details.

Figure 7-84 History Records tab

7.2.7.7 Inspection Results

The same results which were populating in the form view of Inspection Results in text fields

populate in the grid, in the List View. Initial columns indicate the equipment hierarchy and the

rest of the columns show the Inspections i.e. metal loss, corrosion rates, remaining life etc.



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Figure 7-85 Inspection Results tab

7.3 PEMS REPORT VIEW

Inherent reporting functionality is an important part of VAIL-Plant. The report module

comprises of the following pre-defined reports:

Overall Equipment Summery

RISK Matrix Velosi

RISK Matrix (API-RBI)

Risk Ranking Summary

Inspection (History & Analysis)

Plant Inspection Requirement

Number of replacements

Leaks and Defects

Deadleg Summary Report

Deadleg Count Summary

Deadleg Types Count

Anomaly Register Summary

Criticality based Asset Register



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Figure 7-86 PEMS Report View

Below are the steps to access reports.

1. Click on the ‘Report View’ tab on the Outlook bar. A list of pre-defined reports shall

appear.

2. Select the report you want to run by clicking on it. You shall be able to see the

description against each standard report.

3. Define the filters on the right hand side of the screen by selecting the criteria from the

drop down menu.

4. After selecting the criteria, simply click on ‘Preview Report’ button and you can see the

report in the report viewer. If you click the ‘Clear’ button, all the filters are reset. The

below screenshot shows the ‘Risk Ranking Summary (Velosi)’ standard report.



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Figure 7-87 Standard Report

7.4 PEMS USER LIST VIEW

The most customized feature of VAIL-Plant® is the USER LIST View. This provides the facility

to create custom queries to access data from the database manually. The screenshot below shows

the screen when the ‘User List View’ tab on the outlook bar is clicked.



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Figure 7-88 PEMS User List View

You can create your own custom query and save it for future reference. All the previously stored

queries are stored in new Existing Query panel. Finally the grid view shows the result of the

query.

7.4.1 How to create a new query?

1) By clicking on New Query button, a new window will pop up as shown in the figure on

the left below.

Figure 7-89 Left: New Query – Select Table; Right: List of tables



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2) When you click on the drop down box against ‘Select Table’ you will see a list of all

available tables as shown in screenshot above on the right.

3) After you select any table, you will get a list of all available fields in the list box. These

fields are the columns of the tables which contains all records information. Now you can

select the fields you need.

Figure 7-90 New Query - Select Fields

4) Left panel shows all the fields available where as the right panel will show those fields

for which query will be executed. Select the field you want to see in the result and click

the button highlighted in the screenshot below. Repeat this step with all the fields you

wish to appear in the results.

5) Once selected, the field will shift to the right panel to show that it is a selected field to

appear in the result of the query. Once your selection is complete, click the ‘Next’ button.

This is shown in the below screenshots.



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Figure 7-91 Left: New Query - Selected Fields; Right: Next Button

Description of the functions of the buttons on the screen is tabulated below:

Table 7-1 Description of buttons

6) After clicking on Next button a new form will appear as shown below. Provide a name

for this query so as to be able to reuse it from the ‘Existing Queries’ panel at a later time.

Click ‘Finish’ button.

This button moves the selected field from the table to the query result.

This button moves all the available fields to the query result.

This button will move back the selected field from the query result; it means this field

will no longer be available in the result when query will be executed.

This button will bring all the fields back to table and will not show any result after

query execution. It is used to reset the right panel to start over again.



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Figure 7-92 Naming the query

7) After clicking on the Finish button, you will see the query result in the grid view panel.

You can see that the recently made query is also being showing in the Existing Query

Panel.

Figure 7-93 Query saved and Results Displayed



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7.4.2 How to delete an existing query?

1) Select the query you want to delete from the ‘Existing queries’

panel.

2) Click the ‘Delete Query’ button as illustrated alongside.

3) By clicking on this button, selected query shall be deleted and will

no longer appear in the Existing Query section.

7.4.3 How to export the results to excel file?

Export to excel feature will export all the records in the VAIL-Plant® Grid view to Microsoft

Excel file. This allows more usability and easy transfer of the data.

1) When the needed records are being displayed in the grid view, click on the ‘Export’

button at the top of the screen alongside the label ‘Export to Excel’. You may choose to

export only the current page or all the records by selecting the appropriate radio button.

Current Page – Selecting this option ensures that only the records shown on the current

page are exported to excel. This maybe a subset of the entire result set obtained in the

software.

All Records - Selecting this option ensures that all the records in the result set are

exported to excel. This may span a number of pages in the List View.

2) An excel file will open with the grid view records. Save this excel file to use the

information shown in the report.

7.5 REFERENCE DOCUMENTS

This tab of VAIL-Plant® provides the facility to view all the documents under the categories of

AIRMs, SOPs, Operating Manuals and Other Documents. The last sub tab is the Corrosion Rate

Model which links to the excel software for calculation of CO2 Corrosion using the NORSOK

standard. The default tab is AIRMs.

Figure 7-94 Delete Query



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Figure 7-95 Reference Documents

How to view a document?

For any sub tab, the method to view documents remains same. Select the needed document from

the ‘View Documents’ tab to view it on the right of the screen. Click on the ‘View in Separate

Window’ button to open the document in a new window.

How to remove a document?

For any sub tab, the method to remove documents remains same. Select the needed document

from the ‘View Documents’ tab. Click the ‘Delete’ button. You shall be prompted to confirm if

you want to remove the document. Then a message shall appear to report that the document was

successfully deleted.

How to add a document?

Select the ‘Add Documents’ tab. It looks as shown in the below screenshot.



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Figure 7-96 Adding Reference document

Click on the Browse button to select a PDF document from your hard disk. You shall be able to

view it on the right of the screen. Give it a file title, document number and revision number. All

three are mandatory fields. Click on the ‘Add’ button. You shall get a message box saying that

the document has been successfully attached. You shall be able to see the newly added document

in the list of documents in the ‘View Documents’ tab.

Tabs within Reference Documents tab are described below. These are named as they are so as to

provide classification of the documents you upload.

1) AIRMS (Asset Integrity and Reliability Management System)

AIRMS contains all the documents related to Asset integrity & reliability management system.



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Figure 7-97 AIRMS documents

2) SOPs (Standard Operating Procedures)

This tab contains all the reference documents related to Standard Operating Procedures.

Figure 7-98 SOPs



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3) Operating Manuals

You can find all Operating Manuals under this section.

Figure 7-99 Operating Manuals

4) Other Documents

This is a tab to upload documents which do not fall into any of the categories above.

Figure 7-100 Other Documents