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Surface Operations Integrity Management
Bucharest
March 13th 2012
2 Integrated Asset Integrity Management
OMV Petrom Group, the largest oil and gas producer in SEE
Exploration and Production
Romania and Kazakhstan Refining and
Marketing Gas and
Power
►67.77 mn boe total hydrocarbon production
►5.32 bcm Group gas production
►812 mn boe Group proved reserves
►Upstream integrated refining capacity
►~800 filling stations at Petrom Group level
►4.07 mn t Petrom Group marketing sales
►5.05 bcm Group gas sales ►Strong position on the Romanian
gas market, covering all gas market segments
►860 MW Brazi power plant to start commercial operations in H2/2012
All figures as of December 2011; figures refer to Petrom Group
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Exploration and Production Facts and figures
Romania ► Proved reserves at end of 2011 in Romania: 786 mn
boe ► Reserves replacement rate in 2011: 70% ► Crude oil and NGL production in 2011: 33.08 mn bbl
Kazakhstan ► Proved reserves at end of 2011: 26 mn boe ► Crude oil and gas production: 4.36 mn boe
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Definition of ASSET INTEGRITY from OGP
► Asset integrity is related to the prevention of major incidents. It is an outcome of good design, construction and operating practices. It is achieved when facilities are structurally and mechanically sound and perform the processes and produce the products for which they were designed.
► The emphasis is on preventing unplanned hydrocarbon releases that may, either directly or via escalation, results in a major incident.
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Emphasis on Process Safety • Process Safety is a disciplined
framework for managing the integrity of hazardous operating systems and processes by applying good design principles, engineering and operating practices.
• It deals with the prevention and control of incidents that have the potential to release hazardous materials or energy.
• Such incidents can cause toxic effects, fire or explosion and could ultimately result in loss of life, serious injuries, property damage, environmental impact and lost production
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Relationship Asset Integrity & Process Safety
Owned & Assured by HSSE
PSM System AIM
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Integrity Program
Integrity Program to bring facilities up to compliance with regulatory requirements in terms of ► Legal requirements ► Environmental requirements ► Technical condition ► Safety
► Prioritization done based on risk assessment and existing condition assessments
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Integrity Program
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Integrity Management Program
MIRD Program-Fix Derricks
Gas conditioning
Inlet Manifolds, Piping's, Valves Tanks / Habas
Process Safety (PSV’s, Pipework and Venting)
Wellhead X-mas Trees - New Electrical network – power system
ESD&Fire&Gas Detection Pipelines
Boilers & Heaters
H2S and CO2 (detection, escape eqpt. & training of operators)
Replace Boldesti De Gasolinization facility with LTS
Integrity Management Program includes 14 work streams
Technical Documentation Roads Integrity
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Surface Facilities and Pipelines Information and Processes Organization
Asset Integrity
► Risk Based Approach to 2012 High risk facilities (14 work streams, 25 M Euro)
- Mgt of high risk facilities against Earthquake and Flood
- Critical Infrastructure program ► RBI (Static Equipment) and PIMS - Pilot Study Asset 2 High Risk Gas asset - Roll out to all Assets 2012 - Pipeline Prioritization Project for repair and
replacement - Risk Rank High Risk Facilities ► Engineering and Design - Process Safety standard incorporated in design
phase ► Inspection and Maintenance - Maintenance Strategy Review ► Corrosion management - Corrosion Inhibition Program 5000+ wells ► Facility Abandonment - Pipeline Abandonment Program new PI
department
► Technical Documentation - Document Mapping: Identify & develop all
Operational Doc. in HQ, Assets and Projects ► MOC - Eng Change Proced. developed and process in
function ► Permit To Work - Pilot e Permit System Asset X ► Operational Readiness Assurance - Dedicated resource to all new projects ► Process Safety - Safety Critical Elements identified - Perform Stand Brown & Greenfield sites - SAP align, custom FL and WO screens - PS MWA & KPI’s ► IT System & Data Management - ePermit - SCE Database - RBI and PIMS Software - SAP Data Integrity gap analysis ► Audit - PS and SCE Audit
► Organization - Dedicated PIM Team set up in HQ - Pipeline & Static Equipment RBI teams in
Assets - Dedicated PS Resource per asset ► Accountabilities - New JD’s and R&R for new teams in HQ and
Assets - Redefine Operator R&R and first line
maintenance ► Training and Competency - JD redefined for new organization - Training and Competency Matrix to be
developed - Gap Analysis and program establish - RBI Training (Methodology and Software) - Bowtie Risk assessment training complete
Asset Integrity Management Pillars
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Safety Critical Elements
►Safety Critical Element (SCE) - Any part of the facilities (including software) the failure of which could cause or contribute substantially to a major accident, or the purpose of which is to prevent or limit the effects of a major accident.
►Guideline for Identifying Safety Critical Elements - EP-HQ-03-GL-008-OO
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Process Safety Management Plan – Greenfield (Hurezani & Midia)
Risk Assessment
Barriers
Performance Standards
Verify Performance
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Safety Case Major Accident Hazard focused risk assessment report – identifies MAH
Hazard Register describes barriers and SCE are defined.
Issues register is generated
Performance Standards developed and Safety Critical Equipment are identified in maintenance system.
Written Scheme of Verification created and Inspections & maintenance conducted
Safety critical elements are normally identified as a result of a safety case and hazard register development during the design stage
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BOW Tie: Hydrocarbon Containment
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Process Safety Management Plan – Brownfield
OMV SCE Guidelines
Generic Barriers & Analysis
Generic Performance Standards
Verify Performance
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OMV SCE Guideline EP-HQ-03-GL-008-00 for Facilities where no HSE Case exists
SCE are defined using flowchart for identifying safety critical elements
Issues register is generated
Generic Performance Standards developed and Safety Critical Equipment are identified in maintenance system.
Written Scheme of Verification created and Inspections & maintenance conducted
Where a formal risk assessment is not available to identify safety critical elements an alternative approach is required
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Flowchart for Identifying Brownfield SCEs
Guideline for Identifying Safety Critical Elements EP-HQ-03-GL-008-00
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SAP record for Functional Location
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Start up and Year 1 management is crucial for a successful program lifecycle
►SOI department in 2012 is responsible for management, control and execution of a high number of integrity projects with significant impact on Petrom E&P, Operations, HSSE and process safety.
► Different scopes of work with need for alignment & interdependency management between subprojects & work streams
► Need for interaction and coordination with other departments ► High visibility and delivery to Senior Management (significant budget allocation )
►Need for audit proof management processes (incl. documentation) ►Expansion of SOI department scope and project landscape − Pipeline Integrity Team − Petrom Risk Management (Floods & Earthquakes) − Critical infrastructure − Inclusion of all Pipeline and Roads Projects 2013 ►Significant risks to be considered and mitigated ►Review and propose Integrity Program for 2013 (budgets, risk workshops, action plan)
Current situation / challenges
Thank You