[02] Criticality Analysis Conoco Phillips.pdf

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Title

Criticality analysis for maintenance purposes

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1

10

Criticality analysis for maintenance purposes Process correspondence: Anskaffelse, Boring/WS, HMS - risikostyring, Prosjekt, Vedlikehold NORSOK Standard Reference: Z-008 Rev 02, Nov 2001

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Criticality analysis for maintenance purposes

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2

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ADDITIONAL REQUIREMENTS TO NORSOK STANDARD NORSOK standard cross reference list: Z-008 Criticality Analysis for Maintenance Purposes, Rev. 02,Nov. 2001

For information please contact the following: N. Tønnessen - email: [email protected] Tlf. (+47) 52 02 21 47

Document / Revision No.

Owner

Approved

/ Filnavn: 5047CriticalityAnalysis.fm_exp

Utskriftsdato: 03.09.04

Title

Introduction

1

Introduction

1.1

Purpose and Scope

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3

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These additional technical requirements are developed by Phillips Petroleum Company Norway. These additional technical requirements cover requirements additional to the NORSOK Standards as listed under Normative References. The purpose of the document is to define a process for developing a maintenance program for projects and modifications complying with both PPCoN requirements and NPD regulations. Operating experience has given PPCoN knowledge about what level of maintenance that is needed to maintain safe work environment and production availability. For some equipment groups PPCoN and manufacturers have developed maintenance concepts that have proven to be successful in ways of safety, availability and maintenance cost. Detailed maintenance analyses for these groups are not required. For other equipments groups, typically equipment with a large population attending different functions, there is a potential for optimising maintenance effect and resources by using reliability and risk based analysis techniques. This document will give instructions to focus analysis efforts on systems and equipement groups that have a potential for optimising maintenance programs and minimise efforts on systems and equipment groups that allready have been analysed or given a experience based maintenance concept.

1.2

Responsibility The Maintenance Manager is responsible for this document and for ensuring that it is updated or revoked when required by organisational or operational conditions.

1.3

Approval The Manager Operations & Development shall approve the document

1.4

Distribution/revision This document is distributed via Portal for steering documentation on PhilNet Norway.

1.5

Filing/retrieving The record copy (RC) is filed by the Section for Information Logistics.

1.6

Registration This manual as well as the directives is registered with an individual document number in the company's document administration system, which is managed by the Section for Information Logistics.

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Introduction

1.7

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4

10

Handling of non-conformances Deviations shall be handled in accordance with guideline 4929, "Prosedyre for avviksbehandling". All approved/rejected deviations shall be sent to the Technical Document Centre for registering and filing.

1.8

Normative References NORSOK Standards: Z-008 Criticality Analysis for Maintenance purposes, rev 2, November 2001.

PPCoN References: Document 5048N “Krav til sentrale sikkerhetsfunksjoner” Document nr 4920, “Prosedyre for Avviksbehandling”. Document nr 4942 ”Retningslinje for etablering av forebyggende vedlikeholdsprogram” Guide for the application of failure modes, effects & criticality analysis to PPCoN projects revision 3. Guide for the application of reliability centred maintenance to PPCoN projects, revision 2. EkoPLM user guide, issue 4. SAP kokebok “Taskliste” SAP kokebok “Klassifisering av tasklister” SAP kokebok “Maintenance item” SAP kokebok “Vedlikeholdskonsept”

Other References: N/A

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Analysis requirements

2

Analysis requirements

2.1

Workflow

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

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10

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Analysis requirements

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6

10

The workflow of the analysis is split in four main parts; identification of safety functions, identification of ESD valves, the criticality analysis and maintenance program analysis/development. All systems (and all equipment connected) defined in this chapter shall be included in the criticality analysis.

2.2

Safety functions Safety functions, as defined in document 5048N “Krav til sentrale sikkerhetsfunksjoner”, shall be identified for all equipment included and/or influenced by the project/modification. Identified safety functions shall have an assigned function test programme as defined in document number 5048N “Krav til sentrale sikkerhetsfunksjoner”.

2.3

Safety critical ESD valves PPCoN has identified all safety critical ESD valves on all platforms with a corresponding test programe and test procedures. New installation, modification or project changing the premises of the identification must be addressed, evaluated and corrected for. For further details, please contact technical responsible person for valves in PPCoN.

2.4

EkoPLM or NORSOK Z-008 analysis? EkoPLM is a PPCoN developed analysing tool, based on failure modes, effects and criticality analysis (FMECA) and reliability centered maintenance (RCM) analysis methodology. For existing platforms without an EkoPLM analysis and systems not analysed by the EkoPLM tool, analysis shall be done according to NORSOK Z-008. For existing platforms with an EkoPLM analysis, systems analysed by the EkoPLM tool shall be updated when a modification or project influence on plattform performance. For new platforms the EkoPLM analysing tool or equivalent tool subject to PPCoN acceptenace and approval shall be used. Systems not analysed (ref 2.6) shall be covered by a simplified analysis. A simplified analysis include chapter 2.2, 2.3 and assigning a maintenance program as described in chapter 3.1.2 Development of maintenance program for equipment categories not analysed på side 9. In situations where NORSOK Z-008 requires a RCM analysis, the RCM tool of EkoPLM or equivalent tool subject to PPCoN acceptenace and approval, shall be used to document the analysis.

2.5

Decision criteria

2.5.1 EkoPLM analysis Appendix II ”Probability Category and Consequence Code Definitions” in ”Guide for the application of failure modes, effects & criticality analysis” shall be revised by the project to ensure consistent use of decision criteria on the platform, reflecting the criticality of the platform.

2.5.2 NORSOK Z-008 analysis Table 1 and 2 in chapter 5.2.3 of NORSOK standard Z-008 shall be revised by the project to ensure consistent use of decision criteria on the platform, reflecting the criticality of the platform.

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Analysis requirements

2.6

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10

Systems to be analysed The systems to be criticality analysed shall include the following system groups: SYSTEM GROUP 0 - WELLHEADS AND FLOWLINES SYSTEM GROUP 1 - OIL/NGL PROCESS SYSTEM GROUP 2 - GAS PROCESS SYSTEM GROUP 3 - WATER INJECTION RESERVOIR STIMULATION SYSTEM GROUP 4 - OIL AND GAS EXPORT SYSTEM GROUP 5 - PROCESS UTILITY SYSTEM GROUP 6 - PROCESS UTILITY AND FACILITY SUPPORT SYSTEM GROUP 9 - DRILLING Systems of the systemgroups SYSTEM GROUP 7 - SAFETY AND LOSS PREVENTION SYSTEM GROUP 8 - FACILITY SYSTEMS shall be not be analysed. A Maintenance programme is to be assigned as described in section 3.1.2 Development of maintenance program for equipment categories not analysed på side 9.

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Maintenance programme

3

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8

10

Maintenance programme After the criticality analysis NORSOK/EkoPLM define a workprosess leading up to a maintenance program. The kind of analysis required depends on the criticality of the equipment and the availability of allready defined maintenance concepts. In this chapter specific requirements for developing a maintenance program is given.

3.1

Equipment categories and development of maintenance programme

3.1.1 Equipment categories not to be analysed The following equipment categories shall not be analysed (in the RCM part of EkoPLM) to define a preventive maintenance programme, without consulting PPCoN representative prior to the analysis. 1 Air-condition, Refrigeration Equipment 16 Compressors, Vacuum Pumps (main equipment in system group 0, 1, 2, 3, or 4) 19 Lifting and Material Handling Equipment 30 Electrical Motors (main equipment in system group 0, 1, 2, 3, or 4) 31 Power Generating/Transforming Equipment 32 Combustion Engines 41 Heat exchangers (main equipment in system group 0, 1, 2, 3 or 4) 60 Piping, incl. Risers 61 Piping Specialities 63 Gearbox, Power Transmission Equipment (main equipment in system group 0, 1, 2, 3, 4 or 9) 64 Offshore Platform Structures 67 Pumps (main equipment in system group 0, 1, 2, 3, 4 or 9) 80 Communication Equipment 84 Turbines 91 Automatic/Actuator-Operated Valves (defined as safety critical) 93 Safety relief valves 95 Pressure Vessels, Storage Tanks The following categories shall not be included in an EkoPLM analysis. They shall be defined as equipment with consequence class 3 (LOW) in NORSOK Z-008; 10 Buildings and Equipment Containers 13 Computer Equipment 15 Household Equipment 20 Containers, Baskets 21 Lifts and Conveyor Equipment 26 Cables 49 Laboratory-, Hospital Equipment

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Maintenance programme

Page no.

Total

9

10

77 Shop Equipment

3.1.2 Development of maintenance program for equipment categories not analysed Either NORSOK Z-008 or EkoPLM cover the development of an inspection program for piping, structure, pressure vessels, heat exchangers and atmospheric tanks. Reference is made to document TCD2 4314 to NORSOK Z-001 for further details concerning responsibilities for developing inspection programs. PPCoN has developed a set of maintenance concepts based on maintenance and operating experience. The maintenance concepts are available in SAP as Task Lists, and to find the selection of valid maintenance concepts, reports in SAP or an Intranet (PhilNet) report is available. The concepts define maintenance tasks, maintenance task frequency, generic work descriptions and discipline man-hours. After identifying the selection of valid maintenance concepts, a recommendation of the most appropriate concept should be made based on the details of each concept, operating conditions and manufacturer recommendations. The final recommendation from the project, including the requirements defined in document nr 4942 ”Retningslinje for etablering av forebyggende vedlikeholdsprogram”, shall be presented to the Phillips Petroleum Company Norway’s Equipment responsible/PM responsible person for final approval.

3.1.3 Development of maintenance program based on analysis results The development of a maintenance programme based on analysis results shall be according to the chosen methodology (either EkoPLM or NORSOK Z-008).

3.2

Documentation of end product A Word document shall be linked to the platform functional location (for example BD/EKOJ) describing the safety functions, critical ESD valves, decision criteria’s and systems included in the analysis. Database files containing the analysis for each system shall be linked to the platform functional location. On every functional location (tag level) the assigned consequence classes (high, medium, low) for each consequence shall be documented in the classification field of the functional location. The following five fields shall be documented. Example (classification on tag level); Safety class:

High

Production class:

Medium

Environment class:

Medium

Cost class:

Low

Scheduled maintenance

Yes

For EkoPLM analysis results, the highest consequences class for the functional location (tag) identified shall be used, and consequence class 1 and 2 shall be documented in the classification field as ”high”.

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

Title

Maintenance programme

Page no.

Total

10

10

The maintenance program shall be documented in SAP according the requirements described in document nr 4942 ”Retningslinje for etablering av forebyggende vedlikeholdsprogram”.

Document / Revision No. 5047 / 01 Filnavn: 5047CriticalityAnalysis.fm_exp

Owner

Approved

Technical-Director-EkoJ

28.06.02 Utskriftsdato: 03.09.04

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