ISO/TC 67/WG 4 - Reliability Engineering and technology

This document provides requirements and guidance for reporting of production performance data and production loss data in the operating phase by use of production loss categorization. It supplements the principles of ISO 20815:2018, Clause E.3 and Annex G by providing additional details. This document focusses on installations and asset elements within the upstream business category. Business categories and associated installations and plants/units, systems and equipment classes are used in line with ISO 14224:2016, Annex A. The production loss categories given in Annex A are given at a high taxonomic level and supplements the reporting of failure and maintenance parameters as defined in ISO 14224:2016, Annex B.

This document specifies requirements for and gives guidance on the application of life cycle costing to create value for the development activities and operations associated with drilling, exploitation, processing and transport of petroleum, petrochemical and natural gas resources. This document covers facilities and associated activities within different business categories (upstream, midstream, downstream and petrochemical). The life cycle costing process as described in this document is applicable when making decisions between competing options that are differentiated by cost and/or economic value. This document is not concerned with decision-making related to the economic performance of individual options or options differentiated by factors other than cost or economic value. Guidance is provided on the management methodology and application of life cycle costing in support of decision-making across life cycle phases. The extent of planning and management depends on the magnitude of the costs involved, the potential value that can be created and the life cycle phase. It also provides the means of identifying cost drivers and provides a cost-control framework for these cost drivers, allowing effective cost control and optimization over the entire life of an asset.

This document describes the concept of production assurance within the systems and operations associated with exploration drilling, exploitation, processing and transport of petroleum, petrochemical and natural gas resources. This document covers upstream (including subsea), midstream and downstream facilities, petrochemical and associated activities. It focuses on production assurance of oil and gas production, processing and associated activities and covers the analysis of reliability and maintenance of the components. This includes a variety of business categories and associated systems/equipment in the oil and gas value chain. Production assurance addresses not only hydrocarbon production, but also associated activities such as drilling, pipeline installation and subsea intervention. This document provides processes and activities, requirements and guidelines for systematic management, effective planning, execution and use of production assurance and reliability technology. This is to achieve cost-effective solutions over the life cycle of an asset development project structured around the following main elements: — production assurance management for optimum economy of the facility through all of its life cycle phases, while also considering constraints arising from health, safety, environment, and quality; — planning, execution and implementation of reliability technology; — application of reliability and maintenance data; — reliability-based technology development, design and operational improvement. The IEC 60300-3 series addresses equipment reliability and maintenance performance in general. This document designates 12 processes, of which seven are defined as core production assurance processes and addressed in this document. The remaining five processes are denoted as interacting processes and are outside the scope of this document. The interaction of the core production assurance processes with these interacting processes, however, is within the scope of this document as the information flow to and from these latter processes is required to ensure that production assurance requirements can be fulfilled. The only requirement mandated by this document is the establishment and execution of the production assurance programme (PAP). It is important to reflect the PAP in the overall project management in the project for which it applies. This document recommends that the listed processes and activities be initiated only if they can be considered to add value.

ISO 14224:2016 provides a comprehensive basis for the collection of reliability and maintenance (RM) data in a standard format for equipment in all facilities and operations within the petroleum, natural gas and petrochemical industries during the operational life cycle of equipment. It describes data collection principles and associated terms and definitions that constitute a "reliability language" that can be useful for communicating operational experience. The failure modes defined in the normative part of this International Standard can be used as a "reliability thesaurus" for various quantitative as well as qualitative applications. This International Standard also describes data quality control and assurance practices to provide guidance for the user. Standardization of data collection practices facilitates the exchange of information between parties, e.g. plants, owners, manufacturers and contractors. This International Standard establishes requirements that any in-house or commercially available RM data system is required to meet when designed for RM data exchange. Examples, guidelines and principles for the exchange and merging of such RM data are addressed. This International Standard also provides a framework and guidelines for establishing performance objectives and requirements for equipment reliability and availability performance. Annex A contains a summary of equipment that is covered by this International Standard. ISO 14224:2016 defines a minimum amount of data that is required to be collected, and it focuses on two main issues: - data requirements for the categories of data to be collected for use in various analysis methodologies; - standardized data format to facilitate the exchange of reliability and maintenance data between plants, owners, manufacturers and contractors. The following main categories of data are to be collected: a) equipment data, e.g. equipment taxonomy, equipment attributes; b) failure data, e.g. failure cause, failure consequence; c) maintenance data, e.g. maintenance action, resources used, maintenance consequence, down time. NOTE Clause 9 gives further details on data content and data format. The main areas where such data are used are the following: 1) reliability, e.g. failure events and failure mechanisms; 2) availability/efficiency, e.g. equipment availability, system availability, plant production availability; 3) maintenance, e.g. corrective and preventive maintenance, maintenance plan, maintenance supportability; 4) safety and environment, e.g. equipment failures with adverse consequences for safety and/or environment. ISO 14224:2016 does not apply to the following: i. data on (direct) cost issues; ii. data from laboratory testing and manufacturing (e.g. accelerated lifetime testing), see also 5.2; iii. complete equipment data sheets (only data seen relevant for assessing the reliability performance are included); iv. additional on-service data that an operator, on an individual basis, can consider useful for operation and maintenance; v. methods for analysing and applying RM data (however, principles for how to calculate some basic reliability and maintenance parameters are included in the annexes).

ISO 19008:2016 describes the standard cost coding system (SCCS) that classifies costs and quantities related to exploration, development, operation and removal of oil and gas production and processing facilities and to the petroleum, petrochemical and natural gas industry. Upstream, midstream, downstream and petrochemical business categories are included. The SCCS for coding of costs is applicable to: - cost estimating; - actual cost monitoring and reporting; - collection of final quantities and cost data; - standardized exchange of cost data among organizations; - implementation in cost systems. ISO 19008:2016 is intended for users such as the following: a) owner/operator/company (individual or grouped entity that is entitled or contributes to operations in the exploitation of oil and gas fields); b) industry/trade associations; c) manufacturers/contractors; d) cost engineering service contractors, cost system providers, benchmarking providers, etc.; e) authorities/regulatory bodies. ISO 19008:2016 does not apply to the following: 1) cost classification relevant to cost accounting rules, specific contractual agreements, local requirements for cost reporting to national bodies, government rules and tax regulations, authorization for expenditure (AFE), billing purposes etc.; 2) specific project breakdown structures (e.g. work breakdown structures, contract breakdown structures, organizational breakdown structure) or asset breakdowns (e.g. TAG/system codes, area/module breakdown structure) which are and will remain unique. However, this International Standard can provide a basis for the establishment of such specific classification systems.

ISO/TR 12489:2013 aims to close the gap between the state-of-the-art and the application of probabilistic calculations for the safety systems of the petroleum, petrochemical and natural gas industries. It provides guidelines for reliability and safety system analysts and the oil and gas industries. The elementary approaches (e.g. PHA, HAZID, HAZOP, FMECA) are out of the scope of ISO/TR 12489:2013. Yet they are of utmost importance as their results provide the input information essential to properly undertake the implementation of the approaches described in ISO/TR 12489:2013: analytical formulae, Boolean approaches (reliability block diagrams, fault trees, event trees, etc.), Markov graphs and Petri nets. ISO/TR 12489:2013 is focused on probabilistic calculations of random failures and, therefore, the non-random failures are out of the scope even if, to some extent, they are partly included into the reliability data collected from the field.

ISO 20815:2008 introduces the concept of production assurance within the systems and operations associated with exploration drilling, exploitation, processing and transport of petroleum, petrochemical and natural gas resources. ISO 20815:2008 covers upstream (including subsea), midstream and downstream facilities and activities. It focuses on production assurance of oil and gas production, processing and associated activities and covers the analysis of reliability and maintenance of the components. ISO 20815:2008 provides processes and activities, requirements and guidelines for systematic management, effective planning, execution and use of production assurance and reliability technology. This is to achieve cost-effective solutions over the life cycle of an asset-development project structured around the following main elements: production-assurance management for optimum economy of the facility through all of its life-cycle phases, while also considering constraints arising from health, safety, environment, quality and human factors; planning, execution and implementation of reliability technology; application of reliability and maintenance data; and reliability-based design and operation improvement. For standards on equipment reliability and maintenance performance in general, see the IEC 60300-3 series. ISO 20815:2008 designates 12 processes, of which seven are defined as core production-assurance processes and addressed in ISO 20815:2008. The remaining five processes are denoted as interacting processes and are outside the scope of ISO 20815:2008. The interaction of the core production-assurance processes with these interacting processes, however, is within the scope of ISO 20815:2008 as the information flow to and from these latter processes is required to ensure that production-assurance requirements can be fulfilled. ISO 20815:2008 recommends that the listed processes and activities be initiated only if they can be considered to add value. The only requirements mandated by ISO 20815:2008 are the establishment and execution of the production-assurance programme (PAP).

ISO 14224:2006 provides a comprehensive basis for the collection of reliability and maintenance (RM) data in a standard format for equipment in all facilities and operations within the petroleum, natural gas and petrochemical industries during the operational life cycle of equipment. It describes data-collection principles and associated terms and definitions that constitute a "reliability language" that can be useful for communicating operational experience. The failure modes defined in ISO 14224:2006 can be used as a "reliability thesaurus" for various quantitative as well as qualitative applications. ISO 14224:2006 also describes data quality control and assurance practices to provide guidance for the user. Standardization of data-collection practices facilitates the exchange of information between parties, e.g. plants, owners, manufacturers and contractors. ISO 14224:2006 establishes requirements that any in-house or commercially available RM data system is required to meet when designed for RM data exchange. Examples, guidelines and principles for the exchange and merging of such RM data are addressed. ISO 14224:2006 recommends a minimum amount of data that is required to be collected and focuses on the two main issues: data requirements for the type of data to be collected for use in various analysis methodologies and standardized data format to facilitate the exchange of reliability and maintenance data between plants, owners, manufacturers and contractors. The following main categories of data are to be collected: equipment data, e.g. equipment taxonomy, equipment attributes; failure data, e.g. failure cause, failure consequence; maintenance data, e.g. maintenance action, resources used, maintenance consequence, down time. ISO 14224:2006 does not apply to data on (direct) cost issues; data from laboratory testing and manufacturing (e.g. accelerated lifetime testing); complete equipment data sheets (only data seen relevant for assessing the reliability performance are included); additional on-service data that an operator, on an individual basis, can consider useful for operation and maintenance; and methods for analysing and applying RM data (however, principles for how to calculate some basic reliability and maintenance parameters are included).

This part of ISO 15663 provides guidance on application of the methodology for life-cycle costing for the development and operation of facilities for drilling, production and pipeline transportation within the petroleum and natural gas industries. This part of ISO 15663 also provides guidance on the application and calculations of the life-cycle costing process defined in ISO 15663-1.[1] This part of ISO 15663 is not concerned with determining the life-cycle cost of individual items of equipment, but rather with life-cycle costing in order to estimate the cost differences between competing project options.

1 Scope This part of ISO 15663 provides guidelines for the implementation of life-cycle costing for the development and operation of the facilities for drilling, production and pipeline transportation within the petroleum and natural gas industries. This part of ISO 15663 is applicable when making decisions on any option which has cost implications for more than one cost element or project phase. The process can be applied to a wide range of options, particularly when decisions are being considered on the following: — the process concept; — equipment location; — project execution strategies; — health, safety and environment; — system concept and sizing; — equipment type; — equipment configuration; — layout; — maintenance and logistic support strategies; — manning strategy; — manning levels; — operation strategies; — facility modifications; — spares and support strategy; — reuse and/or disposal. This part of ISO 15663 is applicable to all project decisions, but the extent of planning and management of the process will depend on the magnitude of the costs involved and the potential value that can be created. The guidelines will be of value when decisions are taken relating to new investments in projects or during normal operation to optimize revenue.