• LinkedIn Social Icon
  • Google+ Social Icon

© 2019 Houston Integrity Consultants LLC

T-OCA Overview

Our T-OCA software is a fast, efficient, flexible and highly configurable tool for RBI development and management.

 

We originally launched the T-OCA product as an application for dBase III in 1991, and we have worked with technical experts in risk assessment and integrity management around the world for over 25 years to further develop and advance T-OCA.

 

T-OCA has been successfully used within:

Offshore Production
Power Plants
LNG Plants
Chemical Storage
Onshore Production
Pipeline Networks
Petrochemicals
Desalination Plants

T-OCA may be used for RBI program development at design and construction phase, at the end of facility life or any point in between.

We have a technology transfer program where we can provide the necessary expertise and the software tool to allow you or your company to implement and manage risk based inspection programs.  We have provided technology transfer to users worldwide in North and South America, Europe, Africa, Asia and the Middle East.

 

T-OCA is a practical, cost effective system for RBI, with applications across various process equipment and units including piping, static equipment, atmospheric storage tanks, pipelines, rotating equipment, pressure vessels, relief valves and control valves.

 

T-OCA was designed for ease of implementation and for calculation of initial results using built in models to calculate consequences and probabilities of failure from standard equipment technical and process data. The design was to minimize the work done by technical specialists and maximize the work done by trained technicians and technical assistants.

The design of T-OCA includes a process whereby the initial risk assessment may be easily updated from inspection data or other specialist knowledge. T-OCA also includes a module that we call TaskMaster which will automatically generate an inspection task and frequency based on the data in the risk assessment. This provides both efficiency and consistency in the development of inspection and integrity management plans.

 

T-OCA, while simple to use, allows for a high degree of user customization. Examples of the flexible of T-OCA includes:

 

  • It can use a 3x3, 4x4, 5x5 or 6x6 risk matrix.

  • Consequences rule sets have been defined for USA, UK, Australia, and Europe.

  • Probability rule sets are adaptable (e.g Oil and Gas Production, Refining or Chemicals).

  • T-OCA may be configured to use either US or metric units for temperatures, pressures, volumes, pipe diameters, thicknesses and corrosion rates.

 

There are two main functions in RBI, and T-OCA excels at both:

 

  1. Initial risk assessment and development of an inspection plan.

  2. Long term maintenance of the assessment and the inspection plan based on inspection results and other management of change.

We have the ability to compile T-OCA in languages other than English. We have a Spanish version available and can produce other languages on request.

T-OCA Software

 

T-OCA Example

This section provides examples of the T-OCA software, and T-OCA RBI implementation process.

Home Screen

The home screen includes a traffic light system, which shows red, green and yellow based on user selected criteria or queries.

 

Database Configuration

Building an the T-OCA RBI database is a step by step process. At the beginning the database configuration is specified.

Process Units

The process units are identified, defined, and added to the T-OCA Database.

Process Streams

For each process unit, the process streams of varying compositions are defined.

Process Circuits

Process streams are divided into systems (circuits or corrosion loops in other terminology) based on changes in pressure or temperature or changes in material of construction.

Full process circuit descriptions and properties are added to provide additional information for analysis and expert review.

Look-up Table Configuration

The last step before equipment data may be entered is the configuration of the individual lookup tables for the plant.

Process Equipment

Once the Process Streams and the Systems have been defined and the look-up tables configured, the equipment data may be entered or imported. T-OCA provides data input forms for each equipment type, piping, static equipment, rotating equipment, pipelines, atmospheric storage tanks, pressure vessels, pressure safety valves and control valves. We also provide excel files where data can be entered and then automatically imported into the database, which can be more efficient that entering the data one record at a time for large plants.

Initial Assessment

After importing the initial data, we calculate B31.3 for piping and then calculate the initial assessment. The calculate menu has the capability to produce audit reports for individual records. This is useful for diagnosis of problematic results, and we have found over many years that errors in input data lead to inconsistent results.

Risk Matrix Distribution

Once the initial calculation is completed and satisfactory, the database build is essentially complete and will not likely be revisited. Distribution analysis is the first place to look for problems with the initial results. Any records with Consequences or Probability N/D (Not Determined) will be missing some essential values. These can be reviewed, edited and recalculated.

Plant Integrity Review

We use the PIR (Plant Integrity Review) system to manage the database after the initial build. The PIR allows us to make changes and recalculate the risk while maintaining an audit trail that shows the changes, when they were made, why they were made, and by whom.

The PIR form includes sections for changes in Materials, Process, Inspection Results, Consequences of Failure and Probability of Failure. 

The additional data forms allows other files such as drawings or reports to be attached to the database and opened directly from T-OCA.

TaskMaster

TaskMaster allows the user to define a set of standard tasks for each equipment type along with a set of standard intervals and methods.

Each Task is associated with some of the standard methods and intervals.

TaskMaster users develop and maintain a set of rules that the software uses to assign Tasks and Intervals to the equipment. The rules typically call for more frequent inspection of higher risk items and less frequent inspection of lower risk items. When an items risk changes via the PIR process, TaskMaster automatically recalculates the inspection interval and amends the inspection due date accordingly.

TaskMaster will maintain your risk based inspection schedule well into the future.