17
Nov 2020

How Does the Oil and Gas Industry Maintain Operational Efficiency Through AIM?

Asset Integrity Management LifeTech Engineering Ltd

The 2017 annual health and safety data published for UK-based oil and gas industries reports that the industry has been continually improving performance in terms of safety. It also states that in over 50 million man-hours worked offshore, there were only 113 reportable injuries. This is because the government has publicly committed to process safety and asset integrity management.

But how does the industry maintain asset integrity management standards? Can an asset integrity management system in the oil and gas industry help deliver world-class operational performance?

Ideally, asset integrity management involves identifying and reducing safety risks, developing inspection and maintenance plans, and monitoring discrepancies in material conditions while ensuring continuous improvement.

Some of the challenges faced by the oil and gas industry include handling infrastructure that has outlived its original design life, dealing with an ageing workforce, dealing with unplanned outages, etc. Maintaining asset integrity helps avoid unplanned downtime and related safety and environmental incidents.

At LifeTech Engineering, we have implemented asset integrity management programs for oil and gas companies across the world, generating first-class operational performance. We have increased profitability for operators by combining risk-based inspection with corrosion inspection management and data management to reduce risk and ensure timely and accurate decision making.

Our process of assuring asset integrity spans the full lifecycle of the asset. This requires proper planning and experience to maintain integrity throughout the organization. It also ensures that the people, process, and resources required are in place and ready to perform when needed.

A typical asset integrity program includes:

  • Risk-Based Inspection
  • Corrosion management
  • Reliability centred maintenance
  • Condition-based maintenance
  • In-service inspection
  • Non-destructive testing

An asset integrity management system does not exist separately; it works only when all stakeholders have a unified understanding of how asset integrity can be applied to day to day working.

17
Nov 2020

How Does RBI Influence Various Stages of Equipment Life?

Risk Based Inspection LifeTech Engineering Ltd

Risk-Based Inspection (RBI) is used in a wide range of industries to help assess the probability of failure and manage the risk of failure. The RBI assessment identifies the type of potential damage, possible areas where such damage might occur, the rate of such damage, and assesses the impact of such failure. RBI inspection is particularly prevalent in the power and petrochemical sectors. While RBI services contribute to improved safety, they also offer economic benefit by using resources more effectively in the areas of highest risk.

There are four stages of asset/equipment life, with each having its own characteristics and behavior, requiring different management strategies. The four stages include:

  1. Post commissioning
  2. Risk-based
  3. Deterministic
  4. Monitored (old age)

At What Stage Should You Consider RBI Implementation?

Ideally, RBI should be implemented as early as possible in the life-cycle until the asset reaches the Terminal stage since the time between inspections becomes shorter as assets grow older and need more attention.

Can RBI be implemented even before the Post Commission stage, i.e. during a “Stage 0”? Yes, RBI implementation is possible at the design/construction stage, i.e., before you start operating. Implementing RBI at the very beginning of an asset’s life cycle helps minimize potential risks.

Stage 1: The potential for damage is higher because service conditions in the equipment could reveal faults and weaknesses. For instance, fabrication defects, installation stresses, faulty material could surface and require attention.

Stage 2: The asset is at its peak operational life during the second stage. Ideally, at this early stage, there should be few operational issues rates and a stable rate of damage accumulation, however, examinations, inspections, and maintenance will still be required during this stage to make sure equipment is operating as required.

Stage 3: The 3rd stage or the deterministic stage is where equipment has been operational for a substantial time. Equipment is ageing and beginning to show the signs of ageing. You must determine the extent of any damage. At this stage, RBI helps determine the extent and rate of damage, and to estimate the remaining life through Fitness for Service or FFS assessment. The assets have been operating for a while so the damage has been accumulating.

Stage 4: This is the Terminal stage, where assets are approaching their end of life. The equipment will have to be repaired, refurbished, decommissioned, or replaced. Damages are being accumulated, leading to increasing repair. The rate of degradation increases rapidly and could even be difficult to predict. At this stage, RBI assessment helps guarantee adequate safety between examinations and get the best performance out of the equipment. You cannot guarantee future service of the equipment beyond the next examination.

RBI Implementation at The End of Life Stage

RBI inspection services at this stage help gain the most remaining economic benefit from the asset, without causing environmental, personal, or financial risks. But the focus should be on high-risk areas where inspections can reduce risks for the remaining life of the asset. Activities that do not impact risk are usually eliminated or reduced.