ASSET MANAGEMENT & RELIABILITY SOLUTIONS

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ASSET MANAGEMENT & RELIABILITY SOLUTIONS

• Spare Parts Analysis and Usage Forecasting. • Trade Resource Forecasting.

• Lifecycle Maintenance Budget Forecasting. • Maintenance, Inspection and Testing Procedure

Development.

• Computerised Maintenance Management System (CMMS) Upload and Configuration.

Operational Lifecycle Solutions

The operational lifecycle solutions portfolio offers owners of current operational assets a comprehensive array of Asset Management and Reliability related skills, products and services. The spectrum encompasses major supporting roles for client asset management performance improvement programs, providing large scale inspection and condition monitoring services through to ad hoc provision of specialist advice.

Best Practice Audit Services:

• PAS 55 Audit.

• Maintenance Function Best Practice Audit. • NDT / CBM Audit.

Performance Improvement Programs include:

• Maintenance, Inspection and Test Program Re-Development (RCM/RBI/SIL).

• Inventory Management Improvement. • CMMS Improvement.

• Process and Work Flow Improvement. • Business Measurement Improvement. • Defect Management Improvement.

Technical Services:

• Integrity, Materials and Corrosion Engineering. • Reliability Engineering.

• Root Cause Analysis Facilitation.

Asset Integrity Services:

• NDT Technologies and Inspection Services. • Condition Monitoring Services.

Overview

Asset Management is increasingly being recognised as a vital part of any operating company’s push to manage risks and maximise life cycle revenue and profitability. As a result industry business owners are looking for increasingly robust asset management and reliability solutions in both the design and operational aspects of their businesses.

Asset Management and Reliability Solutions

Bureau Veritas has established a vibrant, agile, innovative and independent World-Class Asset Management and Reliability Solutions team delivering expertise globally and across Australia.

With exceptionally qualified consultants, engineers, scientists and technicians, we have one of the strongest asset management capabilities in the Asia Pacific region offering a range of comprehensive technical services. Our core business involves intelligently assessing a client’s asset management, productivity, maintenance and reliability engineering requirements, then applying the most appropriate approaches in order to efficiently and effectively determine optimal solutions and business outcomes.

Products and Services

Bureau Veritas Asset Management and Reliability Solutions offers a full range of products and services across the asset lifecycle, broadly categorised as supporting either design or operational phase outcomes.

Design Phase Solutions

The design phase products and services cover both greenfield and brownfield projects. While the range of services is similar for both project types, it is recognised that brownfield solutions often require a pragmatic approach.

Early Design Phase Solutions:

• Reliability, Availability and Maintainability (RAM) Analysis.

• Integrated Supply Chain RAM Analysis and Value Chain Modelling.

Detailed Design Phase Solutions:

• Reliability Centered Maintenance (RCM). • Risk Based Inspection (RBI).

• Safety Integrity Level and Critical Function Test Assessment.

EARLY DESIGN PHASE SOLUTIONS

RAM Analysis

Through the medium of the Optimise© software Bureau Veritas is able to extend the analysis beyond traditional RAM to provide clients with commercial outputs in addition to the design project outputs. This enables clients to make informed business and design decisions.

Traditional RAM

RAM analysis is traditionally commissioned by design project teams as part of Concept Design, Pre-FEED and FEED. Design teams may also seek RAM analysis in support of debottlenecking or expansion projects. Typically, the objectives of a RAM study are to:

• Analyse, predict and verify the future production performance of a proposed design against target(s). • Identify and quantify critical loss contributors in order to

enable informed design improvement decisions.

Commercial RAM Evaluation

Two notable commercial RAM analysis applications are described below:

Integrated Supply Chain RAM Analysis

Bureau Veritas is able to integrate several isolated facility RAM models into a mega or whole supply chain model. This allows the future performance of the supply chain to be analysed including options such as:

• Shipping operations.

• Delivered product forecasting (profile).

• Delivered product forecasting in a specified future date range.

• Product contract analysis

Investment Decision Optioneering

Furthermore, whole supply chain RAM analysis applied at the pre-project phase can be a powerful tool to support clients optioneer between proposed super projects and better target their investment and project dollar.

Overview

Estimating the future lifecycle performance of operating plant during the concept design phase is critical and integral to a project’s design and commercial decision making process. Bureau Veritas is globally recognised as having taken RAM analysis to a whole new level particularly with regard to early design phase applications.

Optimise© Software

Optimise© is Bureau Veritas’ own RAM Analysis software package developed specifically to predict the future lifecycle performance analysis of a proposed industrial or process plant design. Key features of the Optimise© software are:

• Dynamic Monte Carlo simulator. • Aligned to ISO 20815.

• Determines lifecycle profile of system performance in terms of product quantity delivered.

• Ability to model;

- complex production profiles.

- shipping (port operations and voyage). - multiple delivery points.

- complex operational philosophies. - crew and special equipment mobilisation. - whole supply chains.

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DETAILED DESIGN PHASE SOLUTIONS

Critical Function Test Assessment, CFT

CFT assessment is a facilitated two-part process to identify and analyse Safety Instrumented Functions (SIF). Part one targets the verification of appropriate design principles for each identified instrumented loop according to Safety Integrity Level (SIL). Part two involves the determination of a Critical Function Test (CFT) interval that incorporates instrument voting logic and equipment reliability.

Spare Parts, Trade Resource and Maintenance

Budget Forecasting

Forecasting a maintenance budget, lifecycle spare parts movement and trade resource mix and quantity is possible via a Monte Carlo based RCM approach. This level of RCM analysis is usually applied to greenfield design projects and the larger brownfield projects however, the potential benefits are considerable and the results accurate and astounding.

Overview

Bureau Veritas offers a portfolio of asset solutions for the development of risk-based lifecycle maintenance, inspection and test task strategies, plans, procedures and through-life sparing requirements. The outgoing assessment detail can be configured in the client’s CMMS prior to commissioning all professionally delivered within a strong project management culture.

Large Company Advantage

The intellectual capital for assessment work of this type is derived from Bureau Veritas’ maintenance and reliability engineers, strategists and technical writers. Our global and national operations offer additional depth with ready access to many specialist technicians and engineers.

Design Project Types

Our detailed design phase solutions are equally applicable to both greenfield and brownfield projects, including plant modifications and capital investment projects to sustain operations. We readily tailor our approach to client needs including project scale and complexity.

Maintenance, Inspection and Testing

RCM is perhaps the most widely known of the formal reliability engineering tools. This technique determines exacting routine maintenance programs specifically tailored to the equipment operating context, operational business drivers and risk management requirements. With a thorough and disciplined approach, Bureau Veritas has consistently demonstrated the benefits of RCM. In an industry with mixed experiences and perceptions of RCM, we maintain our reputation using proven techniques while adapting and innovating for each application. We believe that modern RCM has matured into a maintenance and reliability engineering discipline in its own right and offer clients a smart, ‘hard working’ RCM solution that delivers real and implementable results surprisingly quickly.

Risk Based Inspection, RBI

RBI is a facilitated assessment approach to review process piping and vessels in order to identify and treat potential and consequential corrosion damage mechanisms, including Corrosion Under Insulation. RBI software tools co-developed by Bureau Veritas

include FAME+ and RBeye. Fig 3. Predicted Maintenance and Replacement Budget

527 242 382 99 660 83 143 Mechanical Technician Electrical Technician Instrument Technician

Te Rapa Instrument Technician

Operator

Condition Monitoring Technician

Contractor Overall Expenditure $0 $5 0 00 0 $ 00 0 00 $ 50 0 00 $ 200 0 00 $ 250 0 00 $ 300 0 00 2 34 56 78 9 0 Year

Spares Jobs Cor ective Labour Preventive Labour Inspect o n Labour Annual Average

Expenditur

MAINTENANCE BUILD

Bureau Veritas has broad experience with CMMS upload and configuration, offering client assistance with CMMS establishment either as a collaborative exercise or as part of a wider brief.

CMMS Upload and Configuration

Bureau Veritas believes that any risk based maintenance assessment work should not be considered finished until the project outputs are functional in the client’s Computerised Maintenance Management System.

Maintenance Strategy Determination

Perform RCM and RBI Assessments Perform SIL and CFT

Assessments

CMMS Asset Maintenance Build

Develop Asset Register

CMMS Upload Project Management

CMMS Asset Register Criticality Analysis

Project Kick Off Interface Management

Client Project Stakeholders, Client Maintenance Stakeholders, Client Operations Team, Client Maintenance and Reliability Engineering Team, Client Maintenance Process Team, Document Control

Realistic Detailed Planning

Planning Updates, Progress

Steering Group

Persons In Charge

Obtain Asset Name Reservations Asset Names _Reserved

Apply Client Risk Assessment Matrix Facilitate Cr ticality Analysis

Asset Master Data

Apply Any Client Generic Maintenance Strategies

Develop Detailed Maintenance Plans and

Procedures

Extract Any Client Performance Standards Assurance Activities

CMMS Inventory

Audit CMMS Asset Master Data PEFs

P&IDs Site Layout Operations and Maintenance

Philosophy Operations Manual Project Stakeholders Client Operations Team Discipline Stakeholders Client Maintenance Process Team

Document Control

Determine Asset Coding

Project And Discipline Stakeholders Client Operations Team

Complete Engineering Draw ing Set Performance Standards

Equipment Data Sheets Maintenance Manuals Vendor Draw ings Project Stakeholders Client Operations Team Discipline Stakeholders Client Maintenance Process

Team Facility Engineers

Access to: Engineers, Operators and

Technicians [RCM/RBI/CFT Workshops]

Maintenance, Inspection and Testing Plans, Components

Sparing Analysis

Project Stakeholders Client Maintenance Process

Team Facility Engineers

Access to: Client Technicians

Build and Test CMMS Asset Maintenance Data, Construction Type BOMs

Upload CMMS Asset Maintenance, Inspection and Test

Procedures

CMMS Materials Build

Catalogue and Build CMMS Materials Data including Min/Max

CMMS Asset Maintenance Data

CMMS Asset Master Data

Develop Asset Master Data

Vendor Equipment Manuals Vendor parts list GA drgs

Audit CMMS Asset Maintenance Data

Amend / Create Maintenance, Inspection and Testing

Typical Information Supply and Interfaces

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BEST PRACTICE AUDITING

Maintenance Function Best Practice Audit

The Maintenance Function Best Practice Audit shares many similarities with the PAS 55 audit, but with greater emphasis on the maintenance functions for a specific operational plant or site. Audit elements investigated include:

• Maintenance organisation (management, supervision and trades skills).

• Maintenance planning, scheduling and task execution. • Outage planning, control and execution.

• Computerised Maintenance Management System (CMMS). • Materials management.

• Preventative and predictive maintenance. • Reliability engineering.

• Configuration management (design change). • Engineering modifications and capital projects.

NDT and CBM Audits

Provision of NDT and CBM services are core and long standing Bureau Veritas business streams. We are therefore well qualified to conduct thorough audits of this type. Whilst specific in nature, these audits are enablers for identifying improvements such as better work definition, data / information collection, timely and effective secondary activities and

remaining life forecasting.

Benchmark Against Best Practice

Bureau Veritas is internationally known for its compliance, certification and audit capability. This includes the Asset Management and Reliability Solutions series of offerings:

• PAS 55 Comparison / Compliance.

• Maintenance Function Best Practice Audit. • Non-Destructive Testing (NDT) Audit. • Condition Based Maintenance (CBM) Audit. Our goal with these audits extends beyond the audit report, as we seek to empower our clients to achieve best practice through developing an asset management performance improvement roadmap. This encapsulates the series of gap closing, prioritised and resource-considered projects and activities required to achieve best practice.

PAS 55 Comparison / Compliance

The PAS 55:2008 Standard outlines the asset

management elements and aspects that individually and collectively describe best practice. The PAS 55 audit is therefore a holistic and comprehensive review of a client’s asset management business functions evaluated against current best practice.

The scoring mechanism used for the many PAS 55 elements is defined in terms of Asset Management ‘maturity’ against pre-defined levels between 0 and 4.

ASSET MANAGEMENT PERFORMANCE

Best Practice Implementation

Our holistic understanding and technical capability is represented by the diagram below, communicating our

potential to add value to client asset management performance improvement programs. Identified shortfalls in best practice gaps can be large or small, so we readily tailor the scale of our participation in accordance with client business drivers. Typical role examples performed by Bureau Veritas include (but are not limited to):

• Gap Analysis (Benchmark Against Best Practice Audit). • Key roles on client defined improvement projects

(example: Maintenance Improvement). • Time saving methods and tool development.

• Co-opting specialist advice into client initiatives and continuous improvement programs.

The Challenge

Asset intensive businesses are under ever-increasing pressure to deliver improved returns on the investment made in their physical assets, while subject to downward pressure on available resources, time and budgets. This drives the need for continual improvement in asset management performance.

Collaborative Change Management

Philosophy

Bureau Veritas Asset Management and Reliability Solutions understand the importance of achieving performance improvements that are lasting and sustainable. Bureau Veritas is uniquely placed to offer a service centred on intelligent collaboration throughout the change management process. This collaborative approach ensures that effective change is achieved, owned and sustained by the workforce; with genuine support delivered when and where required.

Pla nn ing and Sched ulin g Maintenance Improvement Bus_ines s M as em ent Sys_tem s Mainte nanc e Practice s De fe ct Elimination Program Plant Modif icatio n Warehouse Practices Asset Register Equipment Criticality RCM /

PMO Detailed Work

Instructions and Procedures Spare Parts Optimisation CMMS Upload and Clean Up Break In Work Capacity Planning Work Priority KPIs Debottlenecking Flawless Start Up Select Project OEE Root Cause Analysis Bag & Tag Lubrication Alignment Condition Montioring Failure Reporting Reliability Reporting Design Out Operational Handover Deliverables House Keeping Safety Equipment &

Special Tools _{Issue and}

Control Laydown Areas Role Definition Process Work Close Out 6 Biggest Losses

Benchmark Against Best Practice Audit

0 00 0 00 20 00 30 00 40 00 50 00 60 00 70 00 80 00 90 00 100 00 Maintenance Organisation

Maintenance Planning & Scheduling Maintenance Control and Execution Major Shutdown Management CMMS Materials Management Preventative & Predictive

Maintenance Reliability Engineering Configuration & Documentation Management

Engineering Support & Interaction DCS Data Pla nn ing and Sched ulin g Maintenance Improvement Bus_ines s Mea sure men_t Sys_tem s Mainte nanc e Practice s De fe ct Elimination Program Plant Modif icatio n Warehouse Practices Asset Register Equipment Criticality RCM /

PMO Detailed Work

Instructions and Procedures Spare Parts Optimisation CMMS Upload and Clean Up Break In Work Capacity Planning Work Priority KPIs Debottlenecking Flawless Start Up Select Project OEE Root Cause Analysis Bag & Tag Lubrication Alignment Condition Montioring Failure Reporting Reliability Reporting Design Out Operational Handover Deliverables House Keeping Safety Equipment &

Special Tools _{Issue and}

Control Laydown Areas Role Definition Process Work Close Out 6 Biggest Losses

Benchmark Against Best Practice Audit

0 00 0 00 20 00 30 00 40 00 50 00 60 00 70 00 80 00 90 00 100 00 Maintenance Organisation

Maintenance Planning & Scheduling Maintenance Control and Execution Major Shutdown Management CMMS Materials Management Preventative & Predictive

Maintenance Reliability Engineering Configuration & Documentation Management

Engineering Support & Interaction

DCS Data

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VERTICALLY INTEGRATED TECHNICAL SERVICES

Where components are cracked, a computer-based defect tolerance assessment will indicate whether the equipment is at risk of sudden failure. With knowledge of the stress fields in the crack region, it is possible to predict the rate of fatigue crack growth to indicate remaining service life.

ARMour® Predictive Maintenance Data

Management

As predictive maintenance programs grow in size, so too does the volume of information needing review, processing, filing and action. ARMour® is a state-of-the-art web based system for holistic management of the predictive maintenance data for your enterprise. Ownership of your maintenance data remains with you; Bureau Veritas simply provides the systems and processes to more effectively manage that data. Benefits of ARMour® include:

• Peace of Mind: Your data is complete, centralised and available to your personnel anytime, anywhere. • Save Time: Eliminate manual filing systems. Advanced

searching helps you determine equipment condition faster and easier.

• Effortless installation: no software to install or hardware to maintain.

• Improved decision making: Compare and correlate the results of ultrasonic testing, inspection, vibration analysis, oil analysis and thermography.

• See the big picture: ARMour® highlights the items in your plant that need attention.

Comprehensive and Integrated Technical

Services

Bureau Veritas offers a comprehensive suite of technical services designed to extract the most from your physical assets while optimising availability for a given level of cost without compromising safety. Figure 7 shows these technical services are vertically integrated into the portfolio of Bureau Veritas capabilities in the following groupings:

• Condition Based Monitoring (CBM). • Strategic Non Destructive Testing (NDT). • Material Sciences.

• Engineering Services.

Equipment Fitness For Service Assessment

Through in-service degradation, or from deficiencies in original manufacture, many types of equipment are at risk of failure from cracking or overload. Optimal Run/ Repair/ Replace decisions require a full understanding of the residual strength and life of the equipment.

The vertically integrated technical services provided by Bureau Veritas allow determination of the remaining integrity and life of degraded or defective equipment. Calculation of stresses can be undertaken using in-house Finite Element Analysis (FEA) capabilities, supplemented with in-situ stress testing and measurement using strain gauge techniques. Statistical methods can identify extreme values of damage from a data sample and can characterise degradation trends.

ANALYSIS AND TESTING

Scanning Electron Microscopy (SEM)

High resolution imaging allows the characterization of individual flaws and features of a fracture surface at magnifications from x100 to x10000 in addition to the examination of microstructural features in polished samples. Incorporating Energy Dispersive Spectrometry (EDS) chemical analysis of a small area or spot can be performed to allow the identification of debris, corrosion products and individual metallographic phases.

Centurion Vibration Analysis

Regular vibration analysis is essential for the reliability of rotating and vibration-prone assets. Increasingly, asset maintenance teams are turning to online solutions for vibration analysis, to reduce safety, cost, accessibility, repeatability and machinery downtime risks.

Centurion is a multi-channel, remote vibration monitoring system. After the hardware is installed it is accessed remotely via the Internet, allowing all vibration monitoring tasks to be performed by technicians wherever they are located. The service also adds an alarm capability, where operators can automatically be informed of events of significance as they happen.

Analysis and Testing Capabilities

Bureau Veritas has a number of powerful analysis and testing capabilities that enable fully informed decision making and improved Asset management practices.

Fractographic and Metallographic Analysis

Fractographic and Metallographic Techniques allow for sample examination, ranging from Stereomicroscopy to Scanning Electron Microscopy (SEM). These tools allow Bureau Veritas to assess surface features, accurately identify failure modes, material microstructures, and corrosion features. Fractographic and metallographic analysis play an important part in quality control and root cause failure analysis directed toward the reduction of waste and improvements in equipment and operational reliability.

Low Power Stereomicroscopy

Visual examination of surface flaws, debris and fracture surfaces is performed with the aid of a low power

stereomicroscope. Surface features can often indicate the type and direction of loading contributing to failure.

Optical Microscopy

Metallographic examination of polished and polished-and-etched samples is performed using modern optical microscopes at magnifications from x50 to x1000 in both transmitted and reflected light mode. This can reveal heat treatment condition and the presence of manufacturing or service related defects. Image analysis and wear debris analysis are also routinely performed.

Fig 8. Example Failure Surface Analysis

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WHOLE OF LIFE ENGAGEMENT

Lifecycle Partnering

Figure 12 outlines the expanded Whole of Life (WoL)

engagement philosophy offered by Bureau Veritas, providing you with the confidence to move forward, regardless of where in the asset lifecycle your organisation is operating. The ability of Bureau Veritas to understand your needs and requirements, then apply tailored, market-focused solutions across the asset lifecycle is enhanced by the capability of our experienced employees and cutting-edge technologies. Our mastery of Asset Management and Reliability Solutions grows with every opportunity we have to deliver solutions to our expanding client base. Our diverse range of clients includes some of the Australian’s best known organisations including Apache Energy, Arrow Energy, BHP, BMA Coal, British Gas, Chevron, ConocoPhillips, Delta Electricity, Queensland Gas, Santos, Woodside and State Government utilities.

Bureau Veritas Capability Growth

The acquisition of CCI Pope, Intico and International Risk Consultants (IRC) in the last 5 years has enabled Bureau Veritas Asset Management and Reliability Solutions to provide an unequalled breadth and depth of professional services across the strategic, tactical and services fields of physical asset management in the Asia Pacific region. Amdel Limited has recently joined the Bureau Veritas group and is Australia’s leading provider of innovative laboratory and technical services. Amdel boasts a strong reputation in one-stop-shop geoanalytical and mineral processing capabilities and also offers leading materials testing and Petroleum laboratory services.

Following this growth in capability, Bureau Veritas has completed an organisational re-design driven by an internal service integration and alignment to client needs.

Fig 12. Whole of Life Engagement Philosophy and Range of Professional Services Environmental Audits Turnaround Optimization

Occupational HSE Mgmnt.

Reliability-centered Maintenance (RCM)

Mineral Analysis

Risk Based Inspection (RBI)

Remediation Management SIL Verification

Strategic Asset Management

Technical Due Diligence

Handover

Consulting

Services

Procurement Services

Condition Monitoring Services NDT Services

Failure Analysis Safety Case Development

Structural Testing

Asset Integrity Management HAZOP / HAZID

Reliability-centered Maintenance (RCM)

Risk Based Inspection (RBI) CMMS Configuration

En

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e

Conc

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Asset Knowledge Management (ARMour ®)

Certification & Quality Assurance

EPCM

Operator

Remediation

Exploration

Environmental Audits

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THE BUREAU VERITAS ADVANTAGE

Competitive Advantage

We specialise in servicing a diverse range of industry clients ranging from small to medium companies, to large international firms and Government agencies across multiple sectors. Bureau Veritas provides services via eight dedicated Business Lines globally:

• Health, Safety & Environment. • Industry.

• Marine.

• International Trade. • Certification. • Consumer Products.

• Inspection & In-Service Verification. • Construction.

By teaming with Bureau Veritas you engage with a seasoned industry partner, capable of scaling to your requirements to ensure you achieve the required competitive advantage, throughout the asset lifecycle.

World Leader

Since 1828, Bureau Veritas has grown and established itself as a leading global professional services

organisation providing Inspection, Auditing, Certification, Consultancy, Laboratory Testing and Conformity

Assessment.

Knowledge and Expertise

The technical knowledge and availability of our qualified local teams mean we are able to provide effectively packaged and targeted support. These strengths are relied upon and valued by our clients.

Network

With a network of 900 offices and laboratories and over 39,000 employees in more than 140 countries, Bureau Veritas serves 370,000 customers from diverse industries across the world.

Personalised Service

Bureau Veritas adapts its service according to your needs and helps you overcome your challenges at lower cost.

CONTACT

For details about this service, please contact

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