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Pipeline Integrity Management
The 360° view
In the early 1990s asset integrity management
was addressed by increasing inspection programmes. In the late 1990s,
increasingly sophisticated IT tools were developed, and today a complex
mix of strategies, IT solutions and inspections are often employed. This
can potentially lead to client dissatisfaction, since from an
operator’s point of view ‘it costs a lot, it’s complicated and we’re not sure we really need it’.
Bureau Veritas attended a conference where an
operator presented on the issues involved in implementing a highly
sophisticated integrity management system. In particular the issue of anticipating difficulties related to methodologies, data, management of
change, etc. In response, Bureau Veritas explained the difficulties of
taking on such a wide scope at once. The operator immediately replied:
“Guys, you have the 360° view, we don’t. You should teach us all that
and warn us!”
No revolution but simply common sense
There are many different definitions of
pipeline integrity management (PIM), including those listed within API
1160 and ASME B31.8S.
As a simple and understood-by-all definition,
the following is proposed: “a system to ensure that a pipeline network
is safe, reliable, sustainable and optimised.”
Bureau Veritas’ PIM step-by-step approach is comprised of the following six stages:
- Policy and strategy: where are you now, where do you want to go and what should you put in place to reach your target?
- Methodology: do you want/need to use a risk-based, threat-based or consequence-based approach or something else?
- Data: start thinking about data collection and modelling only once the policy and strategy, and methodology have been identified.
- Systems and tools: once policy and strategy have been defined, methodology has been selected and data gathered, select the most appropriate tool to use (simple or sophisticated software).
- Study and analysis: the tools will enable an assessment of the pipeline network and definition of your inspection plans.
- Inspection and expertise: after implementing the inspection plans, specific expertise should be used to analyse the inspection results. The knowledge gained will then be used during the regular PIM review.
Company policy and methodology is key
As
a first step, it is important to properly define the roots of the PIM
approach chosen. Local constraints, in-house specific requirements,
international guidelines and adequacy will help set up the basis of the
methodology to be developed.
The most appropriate approach will be found by
referencing the local regulatory body’s policy
(safety/inspections-oriented or risk/threat mitigation-oriented) along
with common practices and existing procedures, the assets’ typology and
age, the existing international best practices, and the level of
in-house expertise. Several approaches may be considered, such as
qualitative versus quantitative, threat-based versus damage-based, and
probabilistic versus deterministic.
The identification of expected results (primary
target) should be properly specified: restricted impact on the
environment, corrosion-related failure prevention, inspection strategy,
and means of mitigation. This will ensure that the PIM is set up in-line
with the project targets.
The PIM methodology can then be chosen and tailored to the specific case.
A PIM approach that may be suitable for one operator may not be acceptable for another operator.
Only once the methodology is developed and
understood by all project stakeholders can the data and tool issues be
properly addressed.
Data and tools: you don’t need a video game
Data management is a crucial task within the PIM
process. It should provide a complete system capable of delivering the
right data in the right shape, at the right place and for the right
purpose. This requires very organised and step-wise work.
By
defining the PIM strategy, key performance indicators can be identified
and data requirements can be defined. This refers to the format,
accuracy, and frequency requirements of the data. It is also beneficial
to think mid-term about PIM requirements, for example, consider the
tools that will be used and any modifications that might be planned to
the asset.
Finally, it is advised that data quality
control/quality assurance is performed to obtain the ‘green light’
before processing data into the PIM process.
The same applies to the tools to be used. While
there is a temptation to use a very ‘high tech’ tool, the most important
consideration is for an easy-to-use tool that will monitor the health
of the pipeline network and point out pipeline segments which require
mitigation or inspection due to their threat or risk levels.
Depending on the pipeline’s length, a Microsoft
Excel macro could be sufficient. However, an automated and integrated
tool is necessary for longer pipelines or complicated networks.
Study and analysis: from integrity assessment to inspection plans
Now with an operational and clear pipeline database
along with a PIM tool, the chosen PIM methodology can be implemented.
The PIM tool will enable the first integrity assessment to be carried
out – ‘first’ because PIM is a continuous loop where previous results
are used to improve the following assessments. Following this, a
‘pipeline prioritisation’ can be obtained, which will form the basis to
analyse and understand the pipeline network’s condition. Frrom here, the
PIM can be expanded to include a mitigation plan plus inspection plan.
Here an important question arises: what actions
should be performed in order to reduce the threat/risk level on the
pipeline? Should the inspection frequency be increased, a mitigation
action applied, or both? The decision should rely on the inspection and
mitigation policies defined in the first step of the PIM process.
Inspection and expertise: method qualification and trustworthy results
Undoubtedly,
one of the most visible steps of the PIM process is the inspection
itself. There are many inspection techniques for pipelines but the most
widely used are magnetic-flux leakage and ultrasonic testing. The
in-line inspection provider should be selected very carefully,
evaluating their qualification by referring to the specific requirements
of the project.
The most critical part of this process is the
analysis of results and the expertise required to obtain crucial
information on the actual condition of the pipeline.
An effective PIM should be comparable to a high-quality management system.
This article started by outlining that a PIM is a
system allowing operators to ensure that their pipeline networks operate
in a safe, reliable, sustainable and optimised way.
If neglected and unused, even the most expensive
and ‘high tech’ PIM solution will fail to be beneficial. A PIM needs to
be accepted and embedded into the company’s processes.
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