Through PinnacleART™’s world-class asset integrity programs, our team of engineers and experts can collect, review and verify existing data and processes within a facility, predict failure modes, identify risks, optimize inspections and maintenance tasks, perform specified inspections, validate data and maintain facility performance.
As a result of our asset integrity expertise, clients can minimize risk, optimize costs and improve compliance.
Inspectors typically split piping into “circuits” to categorize piping inventory for inspection, but traditionally, this has been done based on convenience with little thought to corrosion or risk. Instead, PinnacleART™ will either circuitize piping for greenfield facilities or re-circuitize piping for brownfield facilities based on variances in potential damage or risk. For example, PinnacleART™ can define circuits based on temperature, pressure, process or piping metallurgy, with the exact circuitization methodology customized per client based on existing procedures and inspection strategies. Once the circuitization effort is complete, PinnacleART™ will overlay the final set of piping circuits on the facility’s CAD Piping and Instrumentation Diagrams (P&IDs), enabling the inspection department to turn the circuit layer on and off and manage the circuits in CAD, rather than managing them on hardcopy P&ID printouts. In addition, after the electronic circuitization effort is complete, PinnacleART™ will deliver an electronic list of piping circuits and associated line numbers and attributes to help the inspection department manage its piping program.
CML / TML Optimization
After a Risk-Based Inspection (RBI) analysis is complete and all susceptible damage mechanisms have been identified, PinnacleART™’s internal software is used to generate reports recommending the addition and deletion of specific monitoring locations.
In addition, PinnacleART™ can gather all Condition Monitoring Locations (CML) data to be analyzed, use statistical analysis to evaluate the accuracy of the information, and make recommendations for cleanup.
Damage/Corrosion Analysis & Model Diagrams
Potential damage mechanisms, including modeled rates and susceptibilities, are identified for each asset based on a systematic review of design, process, operation and past inspection information. By combining industry standard templates and models (API 581, API 571, Compass Corrosion Guide, NACE Standards, etc.) with PinnacleART™’s damage, corrosion and metallurgical expertise, a theoretical model is produced.
Once the model is built and verified by key facility stakeholders, Corrosion Model Diagrams (CMDs) are created by overlaying the following data on the facility’s systemized Process Flow Diagrams (PFDs): metallurgy, equipment liners, Post Weld Heat Treatment, insulation, operating conditions, projected damage mechanisms and projected damage rates and susceptibilities.
Good data management is essential to system reliability. PinnacleART™ will verify the design, process and inspection information for assets based on the documentation found in electronic and hard copy files at the site. Any hard copy files will be scanned and renamed with a standard renaming structure. The data verified can be uploaded into the Inspection Data Management System (IDMS), a Risk-Based Inspection (RBI) software or provided in a spreadsheet format. The associated design and inspection documentation can then be embedded per asset into the software or linked to a facility server or document management system (DMS).
Design Calculations and Fitness for Service
If equipment documentation is lacking or the current minimum thicknesses are thought to be too conservative, PinnacleART™ can perform design calculations for the vessel by using data-like vessel metallurgy, design/configuration, dimensions and internal processes to output the minimum required thicknesses for the major vessel components. If this data is lacking, PinnacleART™ can send its field teams to strap the vessel and perform a Positive Material Identification (PMI) to feed into the calculation model.
Likewise, if a vessel has seen damage (general corrosion, localized corrosion, cracking, out of roundness, etc.) as specified in API 579, PinnacleART™ can perform Level 1, Level 2 or Level 3 Fitness for Service (FFS) analyses as needed to determine the vessel’s fitness for service and provide recommendations for repair or replacement.
If a facility has a failure, PinnacleART™’s team can perform lab testing and metallurgical evaluation to determine the most probable cause for the failure. Replication, metallography, x-ray analysis and qualitative assessment of remaining life and damage of components in high temperature service can be performed, depending on the type of failure.
Integrity Operating Windows
Since a damage or corrosion study is only as valid as the assumptions upon which it is built, PinnacleART™ will identify ranges and limits of key process variables (i.e. temperature, pressure, velocity and process stream constituents) within each unit and establish parameters in which assets can optimally perform. These operating parameters are prioritized by criticality level (information, standard or critical). PinnacleART™ provides action recommendations with associated response times, ensuring that proper communication channels exist should those Integrity Operating Windows (IOWs) be breached.
Mechanical Integrity Assessment
The purpose of PinnacleART™’s mechanical integrity (MI) assessment is to evaluate how inspection, reliability and all relevant parties effectively manage mechanical integrity at the site. The scope of work includes reviewing key process indicators and plotting them against industry best-in-class benchmarks to determine the effectiveness of the site’s mechanical integrity program. The assessment includes both quantitative and qualitative data gathered from electronic and hard copy files and during interviews with site personnel. The assessment for a single site typically takes three days.
Mechanical Integrity Program Implementation
PinnacleART™ offers clients a mechanical integrity (MI) and Risk-Based Inspection (RBI) program for an entire site’s pressure boundary assets, including pressure vessels, heat exchangers, towers, storage tanks, piping, pump casings, pressure relief valves and critical check valves. The scope of work may include the development of a master asset list for each unit in the plant; gathering all design documentation and inspection history into an electronic library; obtaining process, operating and consequence of failure information; reviewing and validating all design and process data; and entering it into an Inspection Data Management System (IDMS) and/or RBI software program.
The IDMS and/or RBI software will be configured, damage/corrosion assessment performed, Corrosion Model Diagrams (CMDs) created, asset risk profiles generated, Condition Monitoring Locations (CMLs) assigned, and RBI plans developed for each asset. In addition, PinnacleART™ can supplement or completely generate a set of management procedures for the program, including training for appropriate personnel. The time for completion is dependent on the number of assets and the scope of work tailored for each plant.
Pressure Relief Device (PRD) Risk-Based Inspection (RBI)
A Pressure Relief Device (PRD) Risk-Based Inspection (RBI) analysis will be performed for each PRD, utilizing PinnacleART™’s PRD RBI software tool. Design and process information, overpressure scenarios and inspection history will be reviewed and uploaded to the software. Risk will be calculated for both the Fail to Open (FTO) and Leak Cases, and a report will be provided identifying the inspection plans for each PRD.
Program evergreening is necessary to maintain the viability of reliability programs as systems change. PinnacleART™ can assist in ensuring the information contained in the MI/RBI program will be maintained in accordance with the site’s management of change (MOC) program to incorporate any updates to assets. These updates can include, but are not limited to, partial or full replacement of fixed assets, grading of inspection after an inspection is performed, and updates to process and operation information. These updates will be incorporated in the document management system, IDMS/RBI software, circuitized P&IDs, inspection drawings and any other documents deemed critical to the integrity program.
Risk-Based Inspection (RBI) Assessment
Risk-Based Inspection is an approach used to assign risk to particular assets within a facility, and then use that risk to drive inspection strategies. In the oil and gas industry, it is guided by the American Petroleum Institute (API) RP 580, “The Recommended Practice for Risk-Based Inspection”.
PinnacleART™ applies RBI theory in a systematic and standardized manner that provides objective assessments and repeatable results. We also pride ourselves on possessing fluency in a variety of RBI software packages, each of which apply the API 580 concepts in a variety of ways. We are able to both effectively utilize the various packages to perform the RBI assessments, and fully train the owner/operator to manage the RBI process once the assessment is complete.
A Tank Risk-Based Inspection (RBI) analysis will be performed for each atmospheric storage tank utilizing PinnacleART™’s Tank RBI software tool. Design and process information, as well as inspection history will be reviewed and input into the software. A corrosion assessment will be performed, risk will be calculated for the floor, shell courses and roof of the tank, and a report will be provided identifying the inspection plans for each tank.