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PROJECT PLAN
A1
08/09/2013
JK
Draft version
Rev
Date
By
Description
Name
Date
Authorisation
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Project summary
Goal
The purpose of this project is to create a framework and defining a product in relation to corrosion
inspection that uses the knowledge and technology that R2D has "in-house" in order to build a so
called sustainable business
Some important factors :
The implementation of the core business and competencies of the R2D scanning technology.
Parties
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hereafter called R2D
Moranga bvba
presented by Bart Vanclooster
hereafter called Moranga
Nijvelsebaan 17a
3060 Korbeek-Dijle
T : +32 (0)498 73 27 68
M : bart.vanclooster@gmail.com
Targets
In the short term, to bring a product on the market that is profitable for both parties.
On longer term, by the recurring nature of the product to build a sustainable business.
Additionally, to offer a range of additional services that strengthen even more the recurring
character and customer loyalty.
Modalities
This document describes how such a product can be seen in all its facets with the corresponding
edge-services and -activities. It serves as a guide to bring the product on the market.
R2D will provide the practical implementation, as well as marketing, sales and invoicing services.
Moranga will follow-up the projects "behind the scenes". It will also suggest product
improvements, sales strategies, strategic decisions, ...
All assignments are sold/invoiced through R2D. Per assignment Moranga is granted to invoice an
agreed fee of 10% of the total project revenue and is considered as compensation for his services.
Timing
Once a consensus on this document, the product and the modalities exists, the implementation can
be started immediately. Target is to catch up a first assignment in Q4 of 2013.
Continued PROJECT PLAN CIMMP, revision A1
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PRODUCT DEFINITION
Definition
The product is described as to provide a service in which the periodic follow-up of piping systems,
with respect to corrosion, is optimized. This through mapping the entire piping system with the help
of scanning techniques, followed by identifying pipes with similar products . This knowledge
combined with the (pre-)defined corrosion mechanisms results in a series of points that periodically
must be inspected. Our product will optimize these inspections so that a cost effective monitoring
and execution becomes possible.
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atmospheric conditions ?
51. Were the parts that are subject to external corrosion included in an inspection program
in function of the identified corrosion problems ?
Insulation can be a major factor in the occurrence of external corrosion.
Seveso companies are not the only companies that are being followed herein. Another
example can be found in the guidelines of the U.S. Department of Labor, Occupational
Safety and Health Administration (OSHA). This Directive requires inspections and tests to
be conducted according to generally accepted engineering practices. Additionally these
inspections and tests should also documented .
Extract from OSHA 3132, page 19 :
OSHA believes it is important to maintain the mechanical integrity of critical process
equipment to ensure it is designed and installed correctly and operates properly. PSM
mechanical integrity requirements apply to the following equipment.
Controls (including monitoring devices and sensors, alarms, and interlocks), and
Pumps
The employer must establish and implement written procedures to maintain the ongoing
integrity of process equipment. Employees involved in maintaining the ongoing integrity of
process equipment must be trained in an overview of that process and its hazards and
trained in the procedures applicable to the employees job tasks.
Inspection and testing must be performed on process equipment, using procedures that
follow recognized and generally accepted good engineering practices. The frequency of
inspections and tests of process equipment must conform with manufacturers
recommendations and good engineering practices, or more frequently if determined to be
necessary by prior operating experience. Each inspection and test on process equipment
must be documented, identifying the date of the inspection or test, the name of the person
who performed the inspection or test, the serial number or other identifier of the equipment
on which the inspection or test was performed, a description of the inspection or test
performed, and the results of the inspection or test.
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In addition, there are still plenty of reasons why a company would organize such monitoring:
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BASIC VERSION
Definition
In the basic version of the product, the theoretical corrosion study which the customer has available,
is translated into a concrete report which stated what, when, how and how often to inspect. The
customer must work and organize himself in order to realize the inspections.
Concrete implementation
Step 1: inventory of available information
When getting the assignment, the project starts with gathering all available information (define !!!)
from the client. This should include :
Step 2: scanning
When getting the assignment the project starts by scanning the installation. It is important to make
clear agreements with the customer about where the battery limits of the project are located. In this
step, the know-how of R2D is used.
Step 3 : modelling
After scanning the images to be processed . Herein, it is very important to focus on the target of the
command . ln this model does not in detail development of each pipe, device, valve ... a very nice
performance can be achieved in 3D that can be used . than later for other purposes Objective in this
is to create a sort of 3D sketch lines, a sort of general ISO master of the whole installation. They are
namely those ISO's that are needed to identify the location of control. In this master ISO model
must also be shown the platforms as face.
Each additional modelling work can be useful for additional services but in this first basic version,
time and therefore money loss. It is also called the expertise of R2D.
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the inspection points must be done in such a way that they are clearly displayed in the specific ISO
but also are clearly visible in the overall model.
Step 6 : report
A basic implementation of the corrosion inspection program ends with handing over all information
to the customer in a summary report.
This report contains :
The identical 3D model, supplemented with the visualisation of the inspection points
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G. cluster number that identifies with which other points it should be inspected together.
All this in excel or pdf.
The individual ISO per product line with the points of inspection.
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ADDITIONAL SERVICES
It goes without saying that the above already provides an added value, but it is still rather limited.
Additionally, a whole range of additional services can be provided so that added value increases.
Job preparation
Here, the collected information as above, is further developed into a practical workable whole. This
means that the sequences are defined in detail as they have to be carried out . Typical items included
herein are placing scaffolding, stripping insulation, carrying out measurements/inspections ... If
scaffolding should be placed, and where relevant, modified or expanded later on, is also included
herein so that no ambiguity prevails for the scaffolding company. In addition, an estimation of the
required time for each step is included so that a good budgeting and scheduling becomes possible.
Delivered to the customer is a document, which describes in detail, the operation per cluster of
activity. At the request of the customer, it can also include information about neighbouring pipes.
Implementing in CMMS
Due to the large amount of data, an implementation in a Computerized Maintenance Management
System is almost indispensable. Therefore Moranga can supply the data to the customer into an in
advance agreed format. This ensures that the customer has all the data, at all time available in his
own system.
Practical implementation
In the above, everything was prepared so that an inspection / thickness measurement may be
executed. The next step in this is the actual implementation. Moranga can provide a service where
she coordinates all the necessary steps to perform, and for this cooperates with the "home-suppliers"
of the client. Naturally, this will then proceed according to the established procedures in previous
steps.
Before this service can be started, the customer need to agree to the proposed method by Moranga.
Also releasing the work area still belongs to the responsibility of the client.
Whenever, alongside thickness-measurements also visual inspections are requested or required, a
consultant can be provided.
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by the customer (MOC procedures) or combined via re-scans and comparison routines.
Layout drawings
Also, layout drawings are resulting from the model, similar to the PID's.
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full suite
ln this service a total package is offered to the customer, in which everything starts from a 3D
model that is created based on scan-data. Practically the offered services herein are as per following
Developing in detail the procedures that define how inspections should be carried out
Reporting per pipe or device of the findings, corrosion rates and trends
Regularly providing info for upload in the CMMS system of the customer
This is a comprehensive approach that aims at a long-term partnership with the customer.
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Many companies offer corrosion studies and help the customer identify where corrosion can
occur. However, these remain in 95 % of the cases studies that form the basis for a
preventive maintenance program, but they are not detailed enough to be used as-is
immediately. The services of Moranga ensure that translation.
The services offered, are not part of the customer's core business, but however they have to
happen. in one way or another Through addressing these in a coordinated manner, this
provides time savings and a clear structure for the customer.
Often the documentation is incomplete, and so, much time is wasted searching for
information that is not existing. Rarely, for all pipes ISO's are available. Which either can
result in pipes being overlooked, either weaknesses are not identified (eg dead end
corrosion). Note : Having ISO's for all pipes is not a legal obligation.
While the customer can focus on things that can produce money for him, he can as well
always evaluate the status of the process installation in respect to corrosion with full
knowledge.
At first sight, having a 3D model of the plant, seems to difficult to maintaine. Through the
services of Moranga, that burden is removed at an agreed cost, while the customer can fully
benefit of having such a system. Obviously this is the cornerstone of the inspection
preparations and successions. Furthermore labor preparations can be executed more
efficiently, project realizations that can be prepared better, risk analyzes be performed in
more detail, turnaround schedules that can be simulate in a model ...
To do a full monitoring of the installations it soon takes some reliability engineers full-time
occupied. This service ensures that these people can focus on finding solutions to the real
problems instead of spending precious time on coordinating measurement campaigns.
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Corrosion loops are typically defined from a corrosion study. This means that the source
information is taken from PlD's in which circuits with similar corrosion mechanisms be
distinguished. These are not at the level of an ISO. The customer must search for the ISO's
to get the full picture. Suppose that about 60% of all piping has isometric drawings and
those can be found pretty fast. Nevertheless, this will still require a considerable amount of
time before one can be 1OO% certain of the documents found. Since not all documentation
is complete, there is still a lot field-checking left to do. This means another loss of time.
It is almost impossible to get a complete overview of the whole system by only consulting
recorded ISO's This results in imperfections, and this leads to inefficiencies in the
implementation: scaffolding should be adjusted, insulation should also be removed in other
places, the NDT specialist should come back, production people need to prepare extra work
permits ...
The customer may not have sufficient manpower to properly perform these tasks. It is often
an employee that should handle these tasks ad-hoc, several times a year. Infrequently
performing such tasks also decreases efficiency.
Reporting herein is very important as two consecutive measurements and inspections are far
apart in time. Often in such cases, the reporting remains unfinished, making it unclear what
was observed before. The supplied effort becomes entirely in vain.
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R2D
5 weeks*
5 weeks*
3 weeks
1 week
1 week
3 weeks
2 weeks
12 weeks
8 weeks
6 weeks**
4 weeks
8 weeks
4 weeks
14 weeks
8 weeks
26 weeks
16 weeks
* 5 weeks full time employment means 200 hours of work. Translated, this means that we are
talking about 1 hour per pipeline route. This already is a very optimistic estimate.
** Due to the fact that a total overview is virtually infeasible, it is expected that delays occur in the
implementation of unforeseen additional work. Additionally, a good project price can be stipulated
with the scaffolding-, insulation- and measurement company when preparing smoothly.
This is the necessary time for the preparation and execution. The customer then still has no model
available that he can use, also for other things Also the model of Moranga is specific to the
inspections. A further modelling requires an extra 3 weeks or so.
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PRICING
The sheer costs are difficult to estimate. It is mainly about man hours, extra work due to insulation
and scaffolding, additional movements for NDT technicians and time losses for production people
in releasing the area . These costs are all case and contract specific.
Generally it can be put on the following reasoning. On the basis of the (optimistic) estimate of the
time required in order to establish a system, we notice that a reliability engineer allows 26 working
weeks of his time working . Starting from 44 working weeks, this means 60 % of his time in an
entire working year . The total cost for a permanent reliability engineer as employee can be
estimated at 120k. This sets a reference point for the total cost that can be considered, this should
be somewhere around 72k .
A first proposal may be to offer the Basic version for a cost of 50k. Herein the scanning + basic
model, defining clusters + reporting in tabular form. Estimated time for this is 8 weeks.
For additional services the following can be a first step :
Job preparation
Start from the estimated number of inspection points. For example 200 points with 4 points per
cluster, which means 50 clusters. 50 graphical preparations at a rate of 1 per day at 55euro/hour,
resulting in 22k.
Documentation in CMMS
Providing the documentation in a desired customer format can be again in function of the number of
inspection points. For example, 200 points at 0.5 hours per point, resulting in 5.5k. This item can
be used to offer a commercial discount.
Organizing execution
By the hour at a rate of 55/hour.
Static equipment
Should be reviewed in realtion with available documentation level. ln function thereof a price may
be offered. Generally one can assume 1 day per equipment.
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Layout drawings
Lump sum per layout drawing.
Total
A first basic version + preparation of detailed documents and providing the documentation ready for
upload in CMMS, will cost approximately 77,5k.
Monitoring and processing inclusive, cost of approximately 99,5k + hours for attendance on-site.
Sales argument : a commercial gesture may be made with regard to the additional scanning work in
order to make the model, but the modeling itself will be charged.
At 3 weeks additional modeling this means 84,1k.
For this, one has a complete model and clustered job preparations to perform the periodic
inspections.
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Target customers
The target to sell this product to, is generally any Seveso company in Europe.
Obviously because these companies are required to monitor their process installation, and to do this
in a demonstrable way.
Specificly, can be started with the small and medium sized Seveso companies in Flanders. After
wchich can be (fast) extended in respect to the processing power.
Neither Europe nor being a Seveso company must form a barrier to the application. ldeally would
be found a number of companies, who are active on several siteswhich all (or almost all) have to
comply to the same obligations.
Continued PROJECT PLAN CIMMP, revision A1
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The process industry in general, is a target customer for this application.,Although there must
always be some form of corrosion be present. In this case, there is no point to approach the
company
Marketing
This is a product that requires some explanation to convey to the customer. Events and general
forums can help, but the traditional prospecting and personal approach of individuals seems more
preferred. As a start, originating from a list of Seveso companies in Flanders / Belgium, a list can be
substracted of technical managers, maintenance managers and project managers for those
companies.
Linkedin can offer a great support. The personal approach and contacting these people should open
doors to an explanation of the product and a first step towards sales.
A professional looking website is to ensure that possible customers know very good, at first
glance,what we can, what the added value is and how we work. It should also be ensured that the
website is at the top in a google search assignment.
A brochure need to be created, describing and briefly explaining the various facets of the product.
This can be very similar to the information on the website.
Other products
This is the first product that has many facets. If this product can be successful implemented, new
applications can be developed under the same or new negotiated conditions.
TIMEPLAN
Following next logical steps need to be incorporated :
Additional preparations regarding double check pricing, make website, create brochure.
Approaching customers.
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Starting company.
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SWOT
Strengths
Besides all the above listed reasons R2D provides a service that stops where the most
corrosion studies end, namely in the practical implementation.
R2D has the expertise to deliver a good product based on laser scan data.
R2D can work with a low cost base so that the pricing can be competitive.
Weaknesses
Opportunities
Treads
The scanning and especially the modelling remains a time-consuming and therefore expensive way
to obtain and organize the data. It may seem that pricing is too high for the created added value.
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