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 clients 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 : tuti@atsolusi.co.id;
prihbudihastuti@gmail.com
2. Ahmad Taufik, Ph.D
MP : 08122388433
Email: a.taufik@atsolusi.co.id
taufik.fike@gmail.com

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

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.

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.

Pipeline Integrity Management

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.

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 Analysis

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.

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).

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.

Hazard Identification and

Hazard and Operability Study
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.

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

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.

Gas fire and explosion hazard radius areas and

associated individual and societal fatality rate per
year

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.

Reliability, Availability and,

Maintainability Analysis
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.

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

and Life Time Extension
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.

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

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.

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.

Valve and Flange Integrity Management

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.

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 System

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.

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 companys reputation.
It minimizes business loss due oil leakage.
It reduces risk and promote people and environmental safety

Noise and Vibration Analysis

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.

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 Integrity Management

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 ReCertification 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.

Critical member with

service life 52 years

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.

Gas Dispersion Analysis

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 downwind 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.

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

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).

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 and

Remaining Life Assessment
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).

Finite element modeling on deformed subsea pipeline due to anchor drop

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.

Fire and Explosion Analysis

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.

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

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 (its 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 runrepair-replace-down rate decision making. Remaining strength (MAOP) and remaining life of the
pipeline are then determined.

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.

Corrosion Under Insulation

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 - 4C and 175C, and 2)
material austenitic stainless steel at operation temperature between 50Cand 175C. The
corrosion rate increases with the following condition :
1.
2.
3.
4.

Intermittent or variable (cyclic service) operation of equipment

Temperature variations along the height or length of the equipment
Temperature at which attachments to equipment operate; and
Idle or mothballed conditions

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.

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

Cathodic Protection Online Condition Monitoring

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.

Conventional
Measurement

Remote CP Online
Monitoring Instruments
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.

List of Clients

P.T Perusahaan Gas Negara (Persero) Tbk

PT. Pertamina Gas
PT. Pertamina EP
PT. Pertamina Geothermal Energi
PT. PHE-WMO
PT. MEDCO E&P Indonesia
TOTAL E&P Indonesia
NGL Badak Bontang
BP West Java
WAIJO (Wijaya Karya Adhi Karya - IKPT Joint Operation)
PT. Trans Pacific Petrochemical Indotama (TPPI)
PT. SIEMENS Indonesia
PT. Wood Group Indonesia
PT. Cahaya Anugrah Tama
Conoco Philips Indonesia
Kondur Petroleum
PT. Inti Karya Persada Teknik
PT. Energasindo Heksa Karya
PT. Indonesia Power
PT. Surveyor Indonesia
PT. Bina Rekacipta Utama
PT. LAPI ITB
PT. PGN Solution
PT. Biro Klasifikasi Indonesia (BKI)
PT. Chevron Pacific Indonesia
Exxon Mobile Indonesia
CNOOC
PT. Vale Indonesia (Formerly PT. INCO)
PT. Transgasindo (PT. TGI)
PT. Titis Sampurna
PT. Pupuk Iskandar Muda
PT. Krakatau Daya Listrik