by Nighil MC and Srinivas Mettela, Tata Consultancy Services
Bringing Asset Integrity to Drive Asset Management
Asset integrity and availability are crucial for any Oil & Gas company considering the intense pressure to sustain operations at a high utilization rate. Traditionally, the refineries followed a time-based inspection and maintenance schedule. Additionally, there was a lack of proper system and methodologies to evaluate asset risk and asset deterioration. Absence of an asset management strategy based on a risk profile limits the ability of the company to proactively protect and optimize the performance of its large asset base.
In a first of its kind initiative in India, an asset performance management (APM) was implemented focusing asset integrity management for the Oil & Gas major covering risk-based inspection (RBI) and reliability-centered maintenance (RCM) practices to facilitate the strategies for static and rotary assets. The asset integrity management system (AIMS) has enabled the company to transition from a time based to risk-based strategy of performing inspections supported by a detailed corrosion study. This enabled the company to rank assets based on risk, optimize the inspection scope and to digitize the inspection related documentation. Integration with site SAP provided better tracking of inspection recommendations to closure by providing an interface to create, update and complete maintenance notifications into CMMS. RCM program covered around 2,000 rotary assets where maintenance strategies are developed and integrated to CMMS maintenance plans with risk mitigation.
Refinery units have enhanced the mechanical integrity and reliability of static and rotary equipment by a focused inspection and maintenance strategy. RBI based strategy optimized the inspection efforts in the subsequent TAR as the risk profile recommended non-intrusive inspections for about 32.1% of vessels and 13.6% of heat exchangers. The company has extended RBI/RCM program to cover all of their process units and sustaining the asset integrity practice by revising the inspection/maintenance strategies by re-assessment of risk after the proposed mitigation.
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