Configuration Item Verification Procedures in Oil & Gas

Configuration Item (CI) refers to any hardware, software, or documentation that is essential for the safe and efficient operation of an oil and gas facility.

Verification in this context means confirming that a CI meets its defined requirements and specifications. It involves a series of procedures to ensure the CI is fit for purpose and meets regulatory standards.

Calculating Verification Procedures is not a direct mathematical calculation, but rather a process of defining and implementing procedures. Here's a breakdown of the key steps:

1. Define Scope and Requirements:

• Identify the CI: Clearly specify the hardware, software, or documentation in question. Examples include:
  • Equipment: Pumps, compressors, drilling rigs, pipelines, control systems
  • Software: SCADA (Supervisory Control and Data Acquisition) systems, well management software, production optimization software
  • Documentation: Operating manuals, safety procedures, maintenance protocols
• Define Requirements: Determine the specific functional, performance, and safety requirements for the CI based on:
  • Industry standards: API (American Petroleum Institute), ISO (International Organization for Standardization)
  • Regulatory guidelines: OSHA (Occupational Safety and Health Administration), EPA (Environmental Protection Agency)
  • Company policies: Internal operational standards and safety protocols
  • Project specifications: Specific requirements for the CI within the project context

2. Develop Verification Procedures:

• Inspection and Testing: Designate specific procedures for:
  • Visual inspection: Checking for physical damage, corrosion, or wear and tear.
  • Functional testing: Ensuring the CI performs its intended function as designed.
  • Performance testing: Verifying the CI meets performance parameters (e.g., flow rate, pressure, efficiency).
  • Safety testing: Assessing the CI's compliance with safety requirements and risk mitigation measures.
• Documentation review: Verify the accuracy and completeness of all relevant documentation, including:
  • Design specifications: Confirming the CI design meets the defined requirements.
  • Operating manuals: Ensuring clear instructions for safe and efficient operation.
  • Maintenance procedures: Verifying proper maintenance schedules and procedures.
• Traceability: Establish procedures to trace the CI throughout its lifecycle, including:
  • Procurement: Verifying the source and quality of the CI.
  • Installation: Ensuring proper installation and commissioning.
  • Operation: Monitoring the CI's performance during operation.
  • Maintenance: Tracking all maintenance activities and repairs.

3. Implement Verification Procedures:

• Assign roles and responsibilities: Define who is responsible for conducting each verification procedure.
• Establish reporting mechanisms: Document the results of all verification procedures, including any deviations or non-conformities.
• Implement corrective actions: Address any issues identified during verification, including design modifications, repair, or re-testing.
• Maintain records: Keep detailed records of all verification activities, including dates, personnel involved, and results.

4. Continuous Improvement:

• Regularly review and update verification procedures based on:
  • Lessons learned: Analyze previous verification findings to identify areas for improvement.
  • New technologies: Adapt verification procedures to accommodate new technologies and innovations.
  • Regulatory changes: Ensure verification procedures align with evolving industry standards and regulations.

Example of a Specific Verification Procedure:

CI: New high-pressure pipeline

Procedure:

1. Visual inspection: Verify the pipeline's structural integrity, welds, and coating for defects.
2. Pressure testing: Apply pressure exceeding the design operating pressure to test for leaks and structural stability.
3. Non-destructive testing: Utilize radiographic or ultrasonic methods to evaluate the integrity of welds and materials.
4. Documentation review: Verify the pipeline's design specifications, material certificates, and installation records.
5. Commissioning: Conduct a controlled commissioning process to confirm the pipeline's functionality and safe operation.

Key Considerations for Oil & Gas Specific Terms:

• Safety: Prioritize safety procedures, ensuring the CI poses no risks to personnel or the environment.
• Environmental protection: Incorporate procedures to minimize environmental impact, such as emissions monitoring and waste management.
• Redundancy: Consider the implementation of redundant systems or procedures to enhance safety and reliability.
• HAZOP: Conduct Hazard and Operability (HAZOP) studies to identify potential hazards and develop mitigation strategies.
• Risk assessment: Perform thorough risk assessments to identify and prioritize potential risks associated with the CI.

By establishing robust verification procedures and integrating them into the lifecycle of CIs, oil and gas companies can ensure the safe, reliable, and efficient operation of their facilities.