Asset Integrity

YOUR CHALLENGE

As a mechanical integrity manager, engineer or inspector, how do you know you’re spending your time and money in the right places? Every day, you have to decide how to manage and execute a holistic asset integrity program that effectively reduces your loss of containment risk and ensures compliance with codes and standards in a cost effective way.

Case Study

Read our case study to discover how PinnacleART’s RBI implementation helped a client save $5 million USD over the course of 5 years.

OUR SOLUTION

PinnacleART customizes its services to fit the need of each client. Whether the solution is ongoing fitness for service support or a multi-facility risk-based integrity program implementation, our services support the specific objectives of each facility. Our subject matter experts have years of mechanical integrity program experience, including technology (IDMS and RBI software solutions and integration), risk management, 2D and 3D CAD, inspection strategies, corrosion/damage management, capital projects, turnaround planning, fitness for service and others. These services are classified in one of the four following areas:

1. Strategy: While many owner/operators have a defined strategy for their program, there is often a desire to utilize PinnacleARTs expertise to develop a strategy for their programs. In this process, PinnacleART utilizes its SME base to craft a customized solution that fits the facility’s goals.

2. Assessment: PinnacleART assessments integrate a combination of interviewing facility personnel with quantitative documentation and data sampling to confirm a realistic current state of the program.

3. Implementation: PinnacleART’s implementation tools ensure the end deliverables are produced with quality. These work scopes include piping circuitization, damage modeling, implementing IDMS/ RBI software packages, customizing inspection strategies, developing inspection drawings, CML optimization and a host of other program facets.

4. Support: Our clients utilize PinnacleART to effectively and efficiently run and maintain their integrity programs, which involves performing data management, risk calculations, inspection planning, inspections, engineering decisions and program KPI reporting. In the end, our aim is to support the program as if we own it.

Circuitization

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.

Data Management

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.

Failure Analysis / Root Cause Analysis

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 Program 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.

Asset Specific RBI Approaches

Program Evergreening

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.

Click here to learn more about PinnacleART’s RBI solution.