Company Profile PT at Solusi

Asset Integrity Management System “Managing Risk for Better Life”

PT. AT Solusi

Mega Arvia Building. 4th Floor Jl. Sutan Iskandar Muda, No.29

Kebayoran Lama – Jakarta Selatan Phone : 62-21-7291907

Fax : 62-21-72895251

PT. AT Solusi

AT SOLUSI, is an Engineering Consulting Company specializing in asset risk and integrity management. It has committed to use a state of the art of the methodology, tools and computer software to provide our clients with engineering services in all relevant disciplines. We recognize that clients are our most valued asset, the very reason for our existence. Therefore, we consider them as partners to be treated with high respect.

PT. AT SOLUSI was established in 2005 to consist of highly qualified and experienced group of professionals (engineers, technologist, designer, project managers, project engineering and highly skilled technicians) that retained as key personnel who can assemble specific work teams tailored to address and resolve our client’s needs.

Our Vision

To become a strong and receptable risk engineering company by creating value for customers, employees, and stakeholders through empowered the committed people and innovative technology in engineering, inspection and maintenance services, and at the same time inducing various industries across Nation that run their business safely, reliably and profitably

Our Mission

To provide the highest quality in service in supporting and assisting our client to achieve their excellence in engineering consulting and inspection through implementations of the right concepts, methodologies and tools, and at the same time encouraging the awareness of industrial community in the area of risk, integrity, safety and reliability in order to continuously benefit and profit their own business.

Consulting Services Areas

Quantitative Risk Assessment (QRA) Risk Based Inspection (RBI) Remaining Life Assessment Root Cause Failure Analysis (RCFA) Integrity Assessment (Fitness for Purposes) Facility Integrity Management Pipeline Risk and Integrity Management Cathodic Protection Inspection, Analysis & Design CP Online Conditioning Monitoring Vibration Measurement and Analysis Reliability, Availability and Maintainability (RAM) study Life Cycle cost (LCC) and Maintenance Analysis External Corrosion Direct Assessment (ECDA) Pipeline Leak Detection Fire and Explosion Analysis Gas Dispersion Analysis Reliability Centered Maintenance (RCM)

Contact Us : 1. Prih Budihastuti (Tuti)

MP: 081511490548

Email : [email protected];

[email protected]

2. Ahmad Taufik, Ph.D

MP : 08122388433

Email: [email protected]

[email protected]

ASSET INTEGRITY MANAGEMENT SYSTEM (AIMS)

AIMS is the most advance strategy currently used worldwide to manage the risk and integrity of the facility to the acceptable level at the most cost effective way by bridging and linked all existing reliability, integrity and maintenance method such as RBI, PIMS, and On line Conditioning Monitoring and Structural Reliability, into one integrated system.

As the plant and facility matured and exceeded their design life (aging), many operation challenges are faced by the operators such as increases the risk associated with i) damaging mechanism and rates, ii) an increasingly economic competiveness, iii) more safety and environmental issues, and so on. Therefore, the production availability, and reliability have to be well maintained using the more sophisticated methods. This is true for all process assets such as stationary, rotating equipment and structural components.

To ensure the continuity of the facility operation and to promote asset, people and environmental safety, all aspects of the reliability and integrity of the equipment and structure concept must be maintained at all phases during their integrity cycle as outlined below. To achieve those purposes, AIMS should be implemented by using various tools and practicable and proven methodologies.

RM

Risk Based Inspection (RBI) is a risk method, based on API RBD 581, to determine risk levels by considering the probability of failure or failure rate of the mechanical and pressurized system and the consequences of failures of those equipments. The results are then used to prioritize the inspection and maintenance time interval according to the criticality ranks and/or remaining life of the equipments. RBI is applicable for pressure vessels, piping, in-plant pipeline, tanks, heat exchangers, heater, and other pressurized system where the failure mode is leak or rupture causing the flammable or toxic material to release to the atmosphere, therefore, endangering people safety, environments, and assets.

Risk Based Inspection

Benefit of RBI

It improves the reliability and safety aspects. It increases the effectiveness and efficiency of inspection and maintenance programs. It increase the equipment life time because the damage can be detected and identified earlier

and thus more focus on risk management. It increases operational life time of the equipment (life extension program). It improves the public trust to operator/owner performance because indicate open risk and

integrity management. It increases the company value since reliability is assured. It decreases the inspection and maintenance cost.

PIM is planning, organizing, executing and controlling all pipeline risk and integrity, through inspection and monitoring, and maintenance program in order to operate the oil and gas pipeline safely and reliably in the most cost effective way. It is a process that includes inspection of pipeline facilities, evaluating the indications resulting from the inspections, examining the pipe using a variety of techniques, evaluating the results of the examinations, and characterizing the evaluation by defect type and severity and determining the resulting integrity of the pipeline through analysis. The PIMS backbone is risk management and data management which is generally accompanied by GIS along its ROW.

Pipeline Integrity Management

Benefit of PIM Analysis

It manages company reputation It complies with standard and regulation It increases cost effectiveness in IMR Management It extend pipeline life time because risk is managed It generates managable and documented pipeline system It demonstrates FFS and integrity management It maximizes production It reduces HSE events

Root cause failure analysis (RCFA), or shorter, root cause analysis (RCA) is a systematical and organized, step by step, investigation and analysis of failure component or equipment by involving: i) site visit and observation, ii) metallurgical and metallographic analysis, iii) mechanical properties tests and, iv) chemical composition analysis, v) fractographic study by using scanning electron microscope – SEM (for fracture cases), in order to determine the root cause(s) of the problem and to prevent similar occurence in the future. Sometime the failure is so simple that rigorous analysis is not needed and the oblivious cause can easily be determined. However, other failed equipment are quite complex, and hence, a deep and throughout analysis is required to determine the root of the problem.

Root Cause Analysis

Benefit of RCA Similar occurence(s) can be prevented It improves the reliability, operation and safety aspects It increases the effectiveness and efficiency of inspection and maintenance It increases the equipment life time because the damage can be detected and identified earlier

and thus more focus on risk management. It minimized un-planned shutdown.

Oil heater tubes subject to creep and localized short term overheat caused by fire impingement, and observed microstructure and hardness level. A highly plastically deformed metal grains taken by SEMwas identified (picture below).

Hazard identification and hazard operability study (HAZID and HAZOP) are two of risk assessment methodology itended to identify any possible hazard present during operation. More specifically hazard to the operability is evaluated in terms of people safety from fire and explosion hazard , environment, business loss and asset loss. Having accident types, categories and rates are all identified and screened (mechanical aspects, electrical, drop object, fire & explosion, toxic exposures, etc), the credible hazards are then mitigated though various operation schemes. To be succesful, HAZID and HAZOP are conducted by a group of various engineering disciplines through a well design and structured discussion in series of workshop designed for that purposes.

Hazard Identification and Hazard and Operability Study

Benefit of HAZID and HAZOP

It can identify the accident type and highest accident rates to the operations It can identify the most credible hazards to the people, asset, enviernment and busienss. It improves the people safety and asset. It improves process and operations safety in the design phase. It manages overall HSE planning better

Quantitative risk assessment (QRA) is detail analysis of failure rate (or accident) and consequence of failure (or accident) in facility or plant in terms of people safety, both individual fatality and societal fatality and business loss, in oder to operate the plant safely with acceptable risk levels. QRA consider hazards of the plant mainly in terms of fire and explosion and toxicity. Risk mitigation or aversion is quantified by the most cost effective way using cost per casuality averted (CSA) parameter. QRA is applicable for process plant including onshore and offshore oil and gas facility, power plant, gas compressor stations, petrochemical and refinery plant, onshore and offshore pipelines, and the like.

Quantitative Risk Assessment

Benefit of QRA

Be able to identify various hazards related to fatality and/or busienss loss.

Be able to develop various schemes to mitage the risk to acceptable levels through decreasing equipment/component failure rate or accident rate and consequences of failures or accidents

It improves safety of people and asset along ROW pipeline (in vase of pipeline QRA).

Be able to comply Government rule and regulations concerning people and environmetal safety

Be able to manage risk more cost effcetively.

Gas fire and explosion hazard radius areas and associated individual and societal fatality rate per year

Reliability, availability and maintainability (RAM) analysis is risk approach to determine the target availability (and un-availability) of the facility of plant. Many factors contributing to low availability is identified and determined and, reliability improvement is then proposed accordingly. RAM analysis is performed by using fault tree analysis (FTA) or reliability block diagram (RBD). Highest availability of the facility can be determined by purchasing the highest possible reliable equipment and/or by arranging serial and paralel (redundance) equipment to produce the best combination of equipment arrangement availability and selections. Some of RAM intention is to boost production and to minimize the unplanned shutdown.

Reliability, Availability and, Maintainability Analysis

Benefit of RAM Analysis

It decreases equipment and component failure and increase MTTF/MTBF. It identifies the most critical equipment. It increases maintainability (reduce MTTR). It increases availability and decrease unplanned shutdown

It decreases maintenance cost. It optimizes spare parts /stocking management. It improves safety of people and asset.

Remaining life assessment (RLA) is method and procedure used to predict the remaining life of equipment, structures or facility that have been in service for an extended period of time, usually close to or beyond the design life. The RLA offers a possible tool to estimate the useful remaining lifetime and avoid premature failure or scrapping of the part.

Remaining life assessment is considered to be an attractive method/process for cost reduction and reduction downtime. Once certain damage mechanism affecting the equipment or structures have been identified, then the damage rate should be determined to calculate its remaining life. RLA has often been improperly referred to as “life extension”. Actually this analysis cannot extend the lifetime of the components. It can only assess the useful remaining lifetime, based on the metallurgical examinations and/or mechanical calculation. RLA helps in setting up proper inspection schedules, maintenance and repair plan, and operating procedure.

Life time extension (LTE) analysis is further step or effort to extend the calculated remaining life of the equipment or facility until their economic life is met. The extension procedure could involve various actions of maintenance, repair, replacement, or down rate decision making.

Both RLA and LTE use either detail statistics / probabilistics / reliability calculation or deterministic approach. Various standards CODES, applicable to specifics equipment, machinery or facility, may be employed to arrive at the conclusion.

Remaining Life Assessment and Life Time Extension

Benefit of RLA and LTE

It can improve the reliability and safety aspects It increases the effectiveness and efficiency of inspection and maintenance It increases the equipment life time because the damage can be detected and identified

earlier and thus more focus on risk management It increases operational life time of the equipment (life extension program) It improves the public trust to operator/owner performance because indicate open risk and

integrity management. It increases the company value since reliability is assured and so decrease the annual

insurance cost) It decreases the inspection and maintenance cost

Reliability centered maintenance (RCM) is a systematic, disciplined process to ensure safety and mission accomplishment through assurance of continuity of system functions. RCM process defines: system boundaries and identify system functions, functional failures, and likely failure modes for equipment and structure in a specific operating context. RCM develops a logical identification of the cause and effect and functional failures to arrive at what maintenance task to perform to assure the applicable and cost effective management strategy to reducing the probability of functional failure and associated risk in present operating context. RCM combines some other maintenance procedures resulting in a more reliable strategy. RCM produce task list that contain risk priority number (RPN) and different maintenance methods applicable to facility equipment/components, such as preventive maintenance, predictive maintenance, and run to failure.

Reliability Centered Maintenance

Benefit of RCM

It decreases equipment and component failure and increase MTTF/MTBF.

It can identify failure potential mode and hidden failure earlier.

It increases maintainability (reduce MTTR).

It increases availability and decrease unplanned shutdown

It decreases maintenance cost.

It optimizes spare parts /stocking management.

It improves safety of people and asset.

Valves have very specific job in process piping and pipelines, mainly for regulating pressure and flow rate magnitude and direction. They also serves as safety and release devices to ensure the operation is safe according to design specifications. Since they have multi function, complex and multiple failures, the failure modes varies, and therefore, they should be identified, grouped and prioritized. Therefore the valves and flanges integrity can easily be maintained at the most cost effective way.

Valve and Flange Integrity Management

Benefit of V & FIM Analysis

It decreases valve and flange component failure and increase MTTF/MTBF.

It identifies failure potential mode and hidden failure earlier.

It increases maintainability (reduce MTTR).

It increases availability and decrease unplanned shutdown

It decreases maintenance cost.

It optimizes spare parts /stocking management.

It improves safety of people and asset.

Pipeline leak detection is used to overcome leaking problem frequently faced during oil pipeline operation. When a leak occurs in a pipeline, an alarm should come automatically to give as accurately as possible the location and size of the leak with no-false-alarm. The method of pipeline leak detection is flow and pressure monitoring based on detail oil hydraulics calculations combined with statistical leak detection analysis which are dependent on a variety of factors including pipeline network characteristics, product characteristics, instrumentation and communications capabilities, and economics. The utilization of computer systems (i.e.SCADA) in pipeline monitoring allows the greatest amount ofdata to be collected, analyzed, and acted upon in the shortest amount of time. For these reasons, pipeline leak detection employ, and could be integrated with some form of computer-based monitoring(i.e.SCADA: upstream and downstream) which generally consist of two major elements, instrumentation and a supervisory computer with associated software and communications links.

Pipeline Leak Detection System

Benefit of Pipeline Leak Detection

It can discover oil/gas outage events due to pipeline damage, theft,etc. It generates accurate release alarming (no false alarm). It can identify leak location accurately. It can identify leak dimension and leak rate. It improvesoperational efficiency. It minimizes the liability of pipeline operating companies. It may protect a company’s reputation. It minimizes business loss due oil leakage. It reduces risk and promote people and environmental safety

Noise and vibration analysis (NVA) is detail monitoring, calculation and prediction of noise and vibration generated by rotating equipment or other process parameters within and outside the plants in order to set up safety limit to the people and environment. During the analysis, in order to be more accurate, modeling and simulation using finite element method (computerized fluid dynamics - CFD) is commonly utilized and map or contour of areas affected are then generated.

Noise and Vibration Analysis

Benefit of N & V Analysis

It decreases equipment and component failure and increase MTTF/MTBF.

It can identify failure potential mode and hidden failure earlier related to vibration

It increases maintainability (reduce MTTR).

It increases availability and decrease unplanned shutdown

It decreases maintenance cost.

It optimizes spare parts /stocking management.

It improves safety of people and asset.

Structural integritry assessment (SIM) deal with aging onshore or offshore platform exceeding its design life while its economic value is still beneficial. The SIM may be conducted for Re-Certification program awarded by the Government or Regulator. The assessment is usually started with regular inspection programs such visual tests, NDT, and cathodic protection effectiveness inspection (for those parts submerged below water). Corrosion at splash zones and at joint members and weld location are of particular interest to inspect, in order to detect any possible external corrosion and initiated or propagated cracks that detrimental to the structure. Push over and/or fatigue analysis are performed to ensure that,under existing loading condition, the structure and its components or member can be still sustain static and dynamic or cyclic loading without failure, where the operating stresses are still below those of yield strength of the materials. If the structure fail according to FEM simulation, the reinforcement program then put in place so that the platform can be operated safely.

Structural Integrity Management

Benefit of SIM

It increases the reliability of the platform

It decreasesinspection and maintenance cost.

It optimizes spare parts /stocking management.

It improve safety of people and asset.

Critical member with service life 52 years

Gas dispersion analysis (GDA) is detail calculation and prediction of worst case scenario involving toxic and/or flammable gas leaked from the pressurized system to the environment. Two major categories of gas leak such as plump and puff are considerd. The impacted areas mainly in down-wind direction will be determined and the acceptable limit of toxic concentration will be setup. In facilty, GPA is used to determine the location and number of fire and gas detector, or gas sensor to trigger the installed alarms or other safety devices, in case of accidental gas release before endanger the employee or public areas. During the analysis, in order to be more accurate, modeling and simulation using finite element method (computerized fluid dynamics - CFD) is commonly utilized and map or contour of areas affected are generated.

Gas Dispersion Analysis

Benefit of F&E Analysis

It can eliminate and decrease the HSE occurence.

It can identify the safe area with respect to toxic gas release (downwind direction)

It can identify possible fire and eplossive gas dispersion (downwind direction)

It can identify the safe area with respect to toxic and/or eplossive gas dispersion

It increases safety of people and asset and improve risk management.

Fault tree analysis (FTA) is a systematical failure assessment steps based on deductive reasoning starting from the final or top event to its lower causal events in oder to determine the root cause of the problem. The tree is constructed by using “AND” and “OR” logic gates so that the most probable sequent of events can be determined through those logic gate multiplication. This stepwise resolution of events into immediate causal events proceeds until basic causes (primary causes) are identified. In case of failed component, the top event is the sympton observed (e.g. leak or rupture vessels or pipeline, compressor explosion, etc). In case of design phase the top event is an hypothetical most probable failure modes. In this case FTA is a deductive analysis approach for resolving an undesired events scenarios into its causes. When the failure scenarios involving very complex and multiples failure modes are formulized, a First-Order Cutsets (single events which alone trigger the top event) and the Second Order Cutsets (or higher) can be determined. A Cutset is the name given to each of the combinations of base events which can cause the top event. The shortest cutset is the most dangerous condition that subsequently lead to final failure (top event).

Fault Tree Analysis

Benefit of FTA

FTA can be used to resolve the causes of system failure FTA can be used to quantify system failure probability FTA can be used to evaluate potential upgrades to a system FTA can be used to optimize resources in assuring system safety FTA can be used to resolve causes of an incident FTA can be used to model system failures in risk assessments

Fitness for services (FFS) is detail mechanical calculation to evaluate a defect or damaged component or equipment, found by inspection, in order to determine the remaining strength (in terms of maximum allowable working/operating pressure) and remaining life of mechanical and pressurized equipment. FFS is performed to arrive at run-repair-replace-down rate decision making on defect or damaged equipment or component having dimension beyond design acceptance criterion. Remaining life is estimated by considering its damage rates (e.g, corrosion rate, crack propagation rate or creep rate) to determine the next inspection, maintenance or repair plan. The end of life of component according to FFS calculation does not necessarily means the end of its physical life. When involving defect of weld area (piping, pipeline, etc) FFS is sometimes refer to engineering critical assessment (ECA).

Fitness for Services and Remaining Life Assessment

Benefit of FFS and RLA It improves the reliability and safety aspects . It increases the effectiveness and efficiency of inspection and maintenance. It increases the equipment life time because the damage can be detected and identified earlier

and thus more focus on risk management. It increases operational life time of the equipment (life extension program). It improves the public trust to operator/owner performance because indicate open risk and

integrity management. It increases the company value since reliability is assured and so decrease the annual insurance

cost). It decreases the inspection and maintenance cost.

Finite element modeling on deformed subsea pipeline due to anchor drop

Fire and explosion analysis is detail calculation and prediction of worst case scenario involving fire and thermal hazard and explosion or differential pressure received by the receptor including human and physical asset in case of accidents. It is part of design phase of the gas and oil facility. Fire and explosion analysis are applicable to those plant and facility possible for the following occurences : fire ball, pool fire, boiled liquid explosion (BLEVE), vapor explosion (VPE), trench and jet fire. The safe distance and perimeters are to be determined and recommended by using fire wall or explosion-prof materials and/or other risk mitigation measures.

Fire and Explosion Analysis

Benefit of F&E Analysis

Eliminate and decrease the HSE Occurence.

Identify the safe area with respect to fire radiaion hazard

Identify the safe area wiith respect to explosion hazard

Improve safety of people and asset.

External corrosion direct assessment (ECDA) is one of integrity assessment applicable for underground pipeline. It is intended to evaluate the integrity of pipeline with respect to external corrosion attack (it’s capacity to hold operational pressure safely). It consists of series of close interval potential survey (CIPS), and, or direct current voltage gradient (DCVG), or alternatively, long range ultrasonic test (LRUT) followed up by pipeline section digging for coating defect and metal thinning verification by using UT Scan. ECDA is finalized by FFS assessment to arrive at run-repair-replace-down rate decision making. Remaining strength (MAOP) and remaining life of the pipeline are then determined.

External Corrosion Direct Assessment

Benefit of ECDA

It can identify and qualify the coating defect of the pipeline It can identify the effectiveness of cathodic protection of the pepipeline It improves pipeline integrity through well programmed and cost effective

inspection and maintenance. It reduces the likelihood of pipeline leaking and failure. It improves pipeline remaining life. It increases availability and decrease un-planned shutdown It decreases maintenance cost. It improves safety of people, environment and asset.

CUI is corrosion phenomenon that occur beneath the piping insulator caused by the water ingress and entrapment in the insulation. The material suceptible to CUI is carbon steel, low alloy steel, 300 series SS, and duplex stainless steels. Based on the CUI tendency, it is usually occur in: 1) isolated pipe of steel carbon having operation temperature between - 4°C and 175°C, and 2) material austenitic stainless steel at operation temperature between 50°Cand 175°C. The corrosion rate increases with the following condition :

1. Intermittent or variable (cyclic service) operation of equipment 2. Temperature variations along the height or length of the equipment 3. Temperature at which attachments to equipment operate; and 4. Idle or mothballed conditions

Corrosion Under Insulation

Benefit of CUI Detection and Analysis

It decreases the likelihood of steam piping leaking.

Increase remaining life of the steam piping because the damage rate is identified

Increase availability and decrease the un-planned shutdown

Optimize the thermal and process efficiency since the steam quality (pressure, temperature and the enthalpy) is well maintained

Improve the safety of people and risk of the aging asset

Promote risk based inspection, maintenance and repair of the asset.

Decrease the operation and maintenance cost because the inspection can be prioritized

CUI can be detected by infrared thermograph or thermovison as shown above. The suspected CUI location is then verified by opening the insulator followed by UT inspection to measure any possible metal loss.

Currently most cathodic protection performance measurement are manually operated. Generally, corrosion inspectors visit the test point to measure Pipe to Soil Potential where the test points are mainly located in remote areas, and the pipeline ROW should be inspected by foot. Many transmission pipelines lay in swampy, hilly, and forest areas where the access are difficult and also limited. This result in high transportation cost and time consuming. Moreover, there are always risks associated with remote areas survey including geohazard, climate and wild animal. Therefore, there should be an innovation that the potential measurement can be performed remotely and real time - online condition, either employed from site office or from head office / head quarter through integrated computer system.

CP Online Monitoring Schematic

Benefit of CP - Online Conditioning Monitoring

1. Pipe to Soil Potential can quickly be obtained without the need to come to the Tets Point locations.

2. Maintenance and time can be saved because the data is directly sent to the data base in the office or in control room.

3. Human Error can be avoided in taking pipe to soil potential measurement. 4. Cathodic protection effectiveness can early be monitored and accurately. 5. Pipe to soil potential data can be accessed from anywhere as long as the location

have access to the internet/gprs/gsm, and by using a specific software program, the information can also conviently be monitored through mobile phone.

Remote CP Online Monitoring Instruments

Cathodic Protection Online Condition Monitoring

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