Bureau Veritas (M) Sdn Bhd

Technical Centre South East Asia (TC-SEA)

PROVISION OF RISK AND SAFETY CONSULTATION SERVICES FOR

REPSOL OIL & GAS

PROPOSAL BUREAU VERITASKL 07

REPSOL OIL & GAS MALAYSIA LIMITED

Our Ref: MLS

Ir. Hanafiah Besar

(AIM Lead Engineer)
Issued for 12-June- Shamsul Amri
1 3
Revised Price 2018
& (Head AIMS)
Eric vieth
Yusma Laili Abu Hassan
(Business Development)
APPROVED FOR
ITEM REV. PREPARED BY REVIEWED BY
DESCRIPTION DATE SUBMISSION
NO. NO.
BUREAU VERITAS (M) SDN BHD

Bureau Veritas (M) Sdn Bhd

Level 11, Menara Dayabumi, Jalan Sultan Hishamuddin, 50550 Kuala Lumpur, Malaysia
www.bureauveritas.com | Tel: +60(3) 22678888 | Fax: +60(3) 22672889
 REPSOL OIL & GAS MALAYSIA LIMITED
PROVISION OF RISK AND SAFETY CONSULTATION SERVICES
ITB EF NO: AB19-0023

1. INTRODUCTION

We are pleased to submit proposal for the following scopes:

a) WBS 1: Consolidate and Update Asset Register

i. Perform Data Gathering including CMMS AR, Technical Drawing
ii. Update Asset register List
iii. Conduct site verification for validation AR adequacy
iv. Populate Equipment characteristic Upload Template

b) WBS 2: identify Tag level SECE Equipment which includes site visit verification
and assessment
i. SECE Identification& determine SCE Barrier & group
ii. Conduct SECE review with Client (1 day)
iii. Populate SECE Identification Upload template

c) WBS 3: Develop and update SECE Performance Standards (PS) and Assurance
Task according to FARSI
i. Develop SECE Performance standard and Assurance Task (FARSI)
ii. Prepare PS template for each SCE Tag and identify the Acceptance Criteria
Values
iii. PS Wrokshop with client (1 day)
iv. Populate SECE Identification Upload CMMS Template

d) WBS 4: Reliability, Availability and Maintainability (RAM) Study

i. Development of RAM study Assumption
ii. Construct the RAM Model (MAROS)
iii. Facilitate RAM Workshop

e) WBS 5: Failure Mode , Effect and Criticality Analysis (FMECA) Study

i. Establish system boundary
ii. Carry out CA Assessment
iii. List down allC! & C2 equipment from ECA, Developed equipment boundary &
group
iv. Perform Failure Mode & Effect Analysis (FMEA)
v. Perform Failure classification and Characteristic Analysis
vi. Maintenance Task Analysis (MTA) Selection (ERS)

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 REPSOL OIL & GAS MALAYSIA LIMITED
PROVISION OF RISK AND SAFETY CONSULTATION SERVICES
ITB EF NO: AB19-0023

vii. Transfer the information from the FMEA to FMECA

viii. Classify the failure effects by severity (Change to FMECA severity)
ix. Rank failure mode criticality and determine highest risk items
x. Take Mitigation actions and document the remaining risk with rationable
xi. Follow-up on corrective action implementation / effectiveness

f) WBS 6: Establish and Update of CMMS (SAP) Uploading Template

i. Develop SECE PS Mplan (MIC, Std Text, Mplan, FL class Charateristic, GTL)
ii. Perform integration of SECE PS Assurance Task and PM task by optimising
duplicates task (Transition in CMMS register changes)
iii. Update PM Task Maintenance Plan, General Task List & Standard Text upload
templates in CMMS

Scope of Boundary
This proposal scope excludes existing facilities and any modification to existing facilities.

Reference documents for this proposal:

• EP OE MAN SCE (Rev 1.0 - May 2014)

• EP OE GUIDE OPS (Rev 0.0 - Oct 2013)
• ECA/RIMS/PAM/iPOCS
• ISO 14224 - Collection and exchange of reliability and maintenance data for
equipment
• ITB NO: AB19-0023 – Section 3 SCOPE OF WORK - Work Category 2

3. PROJECT WORK BREAKDOWN STRUCTURE (WBS)

This section describes the following:

 Methodology
 Conditions/exclusions
 Data Requirement

i. Methodology

The work will be carried out by the following steps:

a) WBS 1: Consolidate and Update Asset Register

 Review project main equipment list and all discipline equipment list against
P&ID and other drawings.
 List down all equipment tags items as per ISO 14224 requirement. Listing of

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 REPSOL OIL & GAS MALAYSIA LIMITED
PROVISION OF RISK AND SAFETY CONSULTATION SERVICES
ITB EF NO: AB19-0023

additional equipment tags found from P&ID and other drawings.

 Filling up of Equipment (IE01) & Functional Location (IL01) templates with
all mandatory data.
 Filling up of P&ID/Doc number reference in the equipment list template (e.g.
Sort Field)

b) WBS 2: identify Tag level SECE Equipment which includes site visit verification
and assessment
 Review Bow tie and Generic SCE Register from HSE Case
 Assessment using SCE Identification decision flow (from EP OE MAN SCE)
and develop SCE Identification decision flow for all Equipment Type
 Identify SCE, determine SCE barrier & group. Populate SCE Identification
template.
 Conduct SCE Workshop

c) WBS 3: Develop and update SECE Performance Standards (PS) and Assurance
Task according to FARSI
 Review generic Operation phase PS from EP OE GUIDE OPS
 Develop PS for each SECE group for the plant.
 Update work centre, frequency, duration & manhours.
 Identify Assurance task Target Values for each equipment/system identified
as SECE
 Populate specific SCE PS and target values templates
 Conduct PS Workshop

d) WBS 4: Reliability, Availability and Maintainability (RAM) Study

 Asset register and equipment configuration
 List of production constraints (PM activity, Maintenance Crew,
Transportation time, etc)
 Proposed equipment reliability data (MTTF + MTTR)
 Reliability Block Diagram (RBD) Development (MAROS)
 Dynamic simulation & facilities analysis - Base Case
 Sensitivity case simulation & analysis (One Case)
 Workshop preparation
 Workshop session
 Final Report

e) WBS 5: WBS 5: Failure Mode , Effect and Criticality Analysis (FMECA) Study
 System boundary will be based on Functional Location created in WBS 1.
 Perform the criticality analysis assessment
- type if available. If not in OREDA, estimate or obtain ETBF & ETTR
from previous projects database.
- Carry out safety, environmental & financial consequence assessment
- Carry Risk analysis base on ETBF & consequence
- Assign Risk ranking/Equipment criticality based on Petronas (ECA)
Risk Matrix in Appendix A of iPOCS ECA Guideline

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 REPSOL OIL & GAS MALAYSIA LIMITED
PROVISION OF RISK AND SAFETY CONSULTATION SERVICES
ITB EF NO: AB19-0023

- All safety critical equipment shall be assigned as C1 criticality.

 Develop FMEA for C1 & C2 critical equipment only
 Identify Failure mode and analyse failure effects
 Determine causes of the failure modes
 If available, review RAM, RCM, RBI & IPF or ELSOR result if available
criticality of equipment effected will be based on those studies result.
 Develop manpower involved and man hour required to perform task
 Transfer information from the FMEA to the FMECA
 Classify the failure effects by severity (change to FMECA severity)
 Perform criticality calculations
 Rank failure mode criticality and determine highest risk items
 Take mitigation actions and document the remaining risk with rationale
 Follow-up on corrective action implementation/effectiveness

f) WBS 6: Establish and Update of CMMS (SAP) Uploading Template

 SAP Preventative Maintenance Routine & Tasklist development
- List down all equipment types from MSR & PS reports
- Review and define maintenance objects grouping according to type
and task application level (equipment level, skid level or system
level)
- Populate SAP Maintenance Plan, General Task List & Standard Text
upload templates based on PS

EXCLUSION: List of Specific Activity Procedure & Specific activities procedure as this
requires detail site information & site visit. This is not part of MI Guideline for Project
Stage (WW ALL D 04 031) requirement of baseline SERP during project phase. Should
be added later during operation phase.

ii. Conditions/exclusions

 All correct documents shall be supplied and received on time prior to the start of
the work. Acceptance of document shall be frozen upon starting work; the studies/
development will only be based on the information received.

 BVM will only fill up mandatory data for SAP upload templates. BVM will only fill
up data that are available at start of project (AFC data). This proposal excludes
any changes to the submitted AFC data, change of data may lead to additional
cost & extension of duration (to be agreed before proceed).
 SPIR list will be provided to BVM at start of project. BVM will develop SAP BOM
only based on SPIR.

 Information necessary to perform the scope of work, will be provided to BVM in a

timely manner. Delays will lead to an extension on the project schedule and in

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 REPSOL OIL & GAS MALAYSIA LIMITED
PROVISION OF RISK AND SAFETY CONSULTATION SERVICES
ITB EF NO: AB19-0023

some cases additional cost (to be agreed before proceed).

 SAP PM development will exclude detail procedure and work instruction

development (e.g. excludes isolation, tool, plant, rigs requirement etc). Work
centre, number of manpower and duration for each operation will be provided.

 Reports will be issued in two (2) revisions: Draft (issue for comment (IFC)) and
Final (Issue for Approval (IFA)) only. The Final Report will incorporate the two (2)
rounds of comments. Further comment or revisions will be subject to additional
man-hours which are to be approved by Client before proceed

 ECA for non-SCE only (SCE automatically assigned to C1 criticality).

 SAP uploading is excluded from the scope

iii. Data Requirement:

The information/documentation required to execute the scope of work is listed below (but
not limited to):
a. Latest AFC or as built PFD/UFD, P&ID and Vendor P&ID
b. Design basis/Process Description document (including sparing basis)
c. HSE Case
d. IPF & SIL Report
e. RBI & IRP Report.
f. Cause and effect matrix
g. Electrical & Instrument schematic/SLD
h. Hazardous area classification & Ex-rated Equipment list
i. Equipment Layout (including inside rooms)
j. Safety equipment list & layout
k. Vendor documents & drawings such as O&M manual, GA, sectional etc.
l. Fire and Gas layouts.
m. Safety Equipment and Escape route layouts.
n. Process Datasheet
o. Operation Manuals
p. RAM/RCM report
q. Equipment/Instrument Datasheet
r. Equipment GA
s. Mechanical Catalog/Dossier

5. PROJECT ORGANISATION

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 REPSOL OIL & GAS MALAYSIA LIMITED
PROVISION OF RISK AND SAFETY CONSULTATION SERVICES
ITB EF NO: AB19-0023

The project will be manned by following resources:

Core full time team:
i. Project Manager – 1 person
ii. Lead Engineer – 1 person
iii. Senior Engineer – 2 person
iv. Project Engineers – 5 person
v. PMMS/IT Engineer – 1 person

Support resources
vi. Principal Engineers (as and when required only for technical review & workshops only)

Organisation chart & personnel is as per Figure 2 below.

Figure 2: Organisation Chart

6. DELIVERABLES

The deliverables are as follow:

i. Functional Location & Equipment (Mandatory Fields only) SAP Upload Excel Template
ii. SCE List & Summary Report.

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 REPSOL OIL & GAS MALAYSIA LIMITED
PROVISION OF RISK AND SAFETY CONSULTATION SERVICES
ITB EF NO: AB19-0023

iii. SCE SAP FL Class upload Templates

iv. ECA Equipment Criticality Upload Templates
v. Specific PS and target value Templates
vi. FMEA report for C1 & C2 Equipment
vii. SAP GTL, Stdtext & Mplan SAP Upload Templates

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