Project Name: Risk Based Inspection (RBI) and Supporting Studies
Client: PT. ConocoPhillips Indonesia (Working For PT.LAPI ITB)
Implementation: January 2005 - July 2008

Description

PT SCADA PRIMA CIPTA on behalf of PT LAPI ITB performed risk based inspection and its supporting studies that are currently considered as very important process to give more accurate and detailed map of equipments or assets condition to enhance the integrity of its inspection, operation and maintenance.

We conducted the required risk based inspection and supporting studies of several onshore and offshore facilities operated and maintained by ConocoPhillips Indonesia. This intensive study project service will cover the followings:

1. RBI for Offshore Platform Piping and Static Equipment
2. RBI for Onshore Gas Processing Plant
3. RBI for Onshore Oil Processing Plant
4. RBI for Offshore Fixed Structures
5. RBI for Offshore Floating Structures
6. Provision of Software Tools for RBI studies
7. Provision of Pipe Mechanical Joint Integrity & Valve Maintenance Mana-gement & Database Software
8. Provision of Subsea Inspection Database Software

LAPI ITB has a series of long experiences in serving some studies as well as engineering projects to oil and gas companies especially related to the project of risk based inspection and supporting studies. These projects included material verification, material testing and assessment, the investigation of buckling in the gas-line pipe, material analysis of heat exchanger, material studies for off-shore structures, life extension of subsea pipeline, design analysis of gas production facilities, corrosion mapping of oil processing unit plants, RBI for offshore mechanical and piping, failure analysis of main oil line, field data capture for SCADA system, production information system as well as other information integration services.

The methodology that will be used in this study is mainly based on Det Norske Veritas (DNV) Codes that are especially suitable for offshore facilities, such as DNV-RP-G101 for risk based inspection of offshore topsides static mechanical equipment. On the other hand, API 580 as well as API 581 will be used as the main references for the methodology to perform risk based inspection of onshore facilities. Furthermore, as required by ConocoPhillips Indonesia, to support the information integration in this study, LAPI ITB will use and provide SPLAM (Structure and Pipe Line Asset Manager) database and RBI software to support the risk based inspection study. The software are developed by ITB such that the authorized project personnel related to these applications are generally very familiar with these products and it will not need long time for the software configuration set-up and customization. In this project, LAPI ITB will also propose another application-software called JIMS (Joint Integrity Management System) to enhance the performance of Asset Integrity Management of ConocoPhillips Indonesia. All of these application-software tools are very flexible and have link capability to other applications that may be performed in both directions (data import and export).

The studies will apply the API 581 methodology for Onshore Assets and DNV G101 methodology for Offshore Assets, in order to be consistent with previous RBI studies on COPI assets such as Belanak and Hang Tuah. There will also be quality assurance assessments on the study process and result, performed by independent Asset Integrity Management System consultants.

The studies will be supported by highly-versatile, systematic and flexible RBI software named “PROMIA” (Probabilistic Mechanical Integrity Assessment) that has been a result synergy of various related expertise within SPC. We also provide customized software for Joint Integrity Management, which has the capability to interface with ConocoPhillips’s UltraPipe database

Implementation Benefits

- Significant benefits may be achieved by reducing the number of inspection
- The process is auditable and a clear link is established between inspection and associated risk
- Result from previous inspection can be used for future planning of inspection
- Reduction of inspection will bring down cost, without reducing acceptable safety levels
- Increase Safety
- Reduce Cost
- Maximize Productivity
- Deal with Aging Plants
- Prevent Catastrophic Failures
- From Fixed Inspection Intervals to Flexible
- Risk Assessment with API 581 and DNV G-101
- Software can create and modify Model
- Integrated Reporting System
- Cost Effective
- Easy to Manage
- Single Database for multiple asset
- Single Application for all asset

Scope of Work

1. Establishment of asset register for pressure systems
2. Risk assessments of pressure systems through qualitative, semi-quantitative and quantitative approach based on the criticality and data availability.
3. An updated Risk Register of pressure systems
4. Risk Communication plans
5. Integrated record and information management for pressure systems’ risk management
6. COPI employees’ Development and Training through the dissemination of working risk-based asset management
7. Communications with and endorsement from MIGAS and BPMIGAS on the risk-based implementation strategy

Scope of Supply

1. Project Definition Session

Points to be discussed:

a. RBI Methodology and Procedures
b. Risk Scoring System
c. Software Final Customization
d. Case Study for The Workability of The System

As beginning of the whole RBI process, LAPI-ITB and COPI need to have a defining point for the character of the whole project. It is an activity of consensus that produces results of RBI Methodology and Procedures; Risk Scoring System; Software Final Customization; and Case Study for The Workability of The System. These documents will be plainly written, unambiguous plan of the project in sufficient detail to support a proposal or request to LAPI-ITB to undertake the overall project and also address:

- how the work will be done
- how the project will be organized
- who the key personnel are
- a tentative schedule
- a tentative budget

Onshore methodology document will content of customized and simplified API 581 Level-1, Level-2 and Level-3 as LAPI-ITB initial judgment to COPI facilities at onshore asset (narrative, workflow, parameter tables, formulas, questionnaires, etc), from data requirements to inspection planning process.
Offshore methodology document will content of customized and simplified DNV G101 Qualitative Approach and Quantitative Approach as LAPI-ITB initial judgment to COPI facilities at offshore asset (narrative, workflow, parameter tables, formulas, questionnaires, etc), from data requirements to inspection planning process

2. Defining Primary Philosopy for Asset
3. General Guidelines in Performing RBI for Asset

4. Review, Evaluate and Screening of Information

5. Identify Risk Matrix for RBI

6. Risk Screening (API 581 Qualitative, DNV G-101 Screening)

7.Risk Assessment (API 581 Semi Quantitative, Quantitative, DNV G-101 Detail Assessment)

8. Risk Mapping
9. Inspection Plan
10. Risk Profile and Resource Allocation
11. Inspection Budget Forecast

12. Project Report
13. Joint Study Session

Points to be discussed:

a. Risk Matrix
b. PoF and CoF Criteria
c. Acceptance Criteria
d. Assumptions
e. Level of Depths
f. Reporting Formats
g. Data Clarifications
h. Screening
i. Selected Detailed Analysis

Joint-Study Session (JSS) will be conducted upon each WO issuance as details discussion after Project Definition Session. The session will address:

- risk matrix
- PoF and CoF criteria
- acceptance criteria
- assumptions
- level of depths
- reporting formats
- data clarifications
- screening
- selected detailed analysis

14. Final Report and Presentation