Integrity Management Study for LNG Project

Overview

A major international operator contracted Oceaneering to develop and implement a comprehensive integrated Integrity Management System (IMS) to support a large expansion project at one of their liquefied natural gas (LNG) facilities in Southeast Asia.

Aimed at increasing production in the region, the added infrastructure included offshore gas production platforms, pipelines, and processing facilities. Completed over a three-year period, the IMS incorporates Risk-Based Inspection (RBI), Corrosion Management (CM), Pressure Systems Integrity, Dead Leg Management, Corrosion Under Insulation (CUI) evaluation, Vibration Monitoring, and Fabric Maintenance Strategies, ensuring long-term asset reliability and operational efficiency.

Challenges

To address the many challenges posed by the LNG process, our team implemented a comprehensive strategy that emphasized collaboration and risk management.

By leveraging advanced inspection techniques and integrating digital systems, we successfully mitigated corrosion threats and ensured the integrity of critical components. Our systematic approach and teamwork were key to overcoming these obstacles and maintaining operational efficiency.

Addressing Corrosion and Materials Degradation

The LNG process involves cryogenic conditions, aggressive chemicals, acid gas, steam generation utilities, toxic fluids, and high-pressure hydrocarbon systems, leading to potential corrosion threats such as CO₂-induced corrosion, high-temperature degradation, Microbially Influenced Corrosion (MIC), and Stress Corrosion Cracking (SCC).
External threats such as CUI and Corrosion Under Fireproofing (CUF) pose significant risks to structural components, piping, and pressure systems.

Pressure System Integrity and Baseline Inspection

Dead Leg and Piping Vibration Management

Dead legs, sections of piping where fluid flow is stagnant, are particularly susceptible to internal corrosion, requiring identification, targeted inspections, prioritization, and risk assessment.
LNG facilities, particularly those with insufficient support for small-bore piping and those located close to vibration sources such as unbalanced fan coolers or compressors, are prone to Vibration-Induced Fatigue Failures (VIFF). This necessitated a comprehensive vibration monitoring strategy to mitigate failures in small-bore piping and equipment.

Corrosion Under Insulation (CUI)

In the context of onshore LNG facilities, CUI presents a significant challenge due to the difficulty in inspecting insulated components. Moisture entrapment, aging insulation materials, and environmental conditions can accelerate corrosion beneath the insulation. Specific challenges include detecting early signs of degradation without complete insulation removal, planning for controlled insulation removal during inspections, and implementing effective remedial actions. Advanced techniques such as infrared thermography, ultrasonic testing, and guided wave testing are critical in addressing these issues.

Digital Integration with the Client’s Systems

Our Solution

Our team of engineers implemented a robust and thorough plan to effectively manage the risks associated with corrosion and materials degradation at the facility.

Risk-Based Inspection (RBI) and Corrosion Management

Implemented Risk-Based Assessment (RBA) and RBI Strategies in accordance with the clients’s standards.
Developed Corrosion Control Matrices (CCM) for onshore and offshore facilities, ensuring targeted mitigation actions and real-time monitoring of corrosion rates. Introduced key performance indicators (KPIs) and Integrity Operating Windows (IOWs) to measure and control the major parameters affecting the identified potential and active damage mechanisms. These measures were supported by clearly defined roles, responsibilities, actions, and alarm plans to ensure the program’s practical implementation.
The RBI approach incorporated API 580/581 methodologies, optimizing inspection intervals and minimizing downtime.
The RBA reports highlighted key internal and external threats by considering all potential and active damage mechanisms, such as general metal loss, pitting, cracking, and both metallurgical and mechanical degradation.

Pressure Systems Integrity and Baseline Inspection

Implemented a structured Pressure Systems Integrity Management Strategy (PSIMS) was to establish clear inspection workflows and ensure regulatory compliance.
The baseline inspection program included Ultrasonic Thickness (UT), Phased Array UT (PAUT), and Radiography surveys to detect material loss in critical piping, as well as internal close visual surveys for critical vessels.
RBI reports for pressure vessels and pressure relief devices provided detailed recommendations for inspection and mitigation at various levels: component-level for vessels, group-level for piping, and individual testing requirements for pressure safety valves (PSVs).
Developed individual written Schemes of Examinations (WSEs) and associated work packs, specifying the exact Condition Monitoring Locations (CMLs) and the required inspection techniques based on the applicable damage mechanisms.

Dead Leg and Piping Vibration Risk Management

Conducted dead leg risk assessments to classify stagnant piping sections based on their susceptibility to corrosion, guiding inspection priorities. It was crucial to identify locations that could potentially be eliminated by design modifications and to advise the design team on providing natural draining provisions. This was followed by a detailed survey of isometric drawings to locate and verify dead leg sections, distinguishing between operational and physically isolated dead legs.
Developed vibration management strategies in accordance with Energy Institute (EI) guidelines for small-bore tubing and process piping.
RBI data indicated that fatigue damage was a key failure mode in dead legs and small- bore piping, emphasizing the importance of periodic vibration monitoring.

CUI Management Program

Developed a comprehensive register listing all insulated items (including partially insulated components such as vessel trims). Each item was assigned a risk rating based on its unique temperature profile, complexity, and anticipated operational cycles.
Formulated a dedicated inspection plan was formulated, incorporating the need for partial or full removal of insulation to facilitate accurate assessment and timely maintenance.

Digitalization and Integrity Data Integration

Fabric Maintenance Strategy

Sand Management Program

Results

Our team played a critical role in developing and executing a comprehensive Integrity Management System for the project. By leveraging advanced risk-based methodologies, digital integration, and proactive inspection strategies, Oceaneering ensured that the new LNG assets are supported by a sustainable and data-driven integrity management framework. The systematic approach led to significant improvements in integrity management and risk mitigation.

Optimized Asset Integrity and Corrosion Control

The Corrosion Risk-Based Assessment (RBA) and inspection strategy provided a data-driven approach to corrosion monitoring and prevention.
Early identification of high-risk corrosion circuits allowed for proactive mitigation, preventing unplanned shutdowns.

Enhanced Inspection Efficiency and Reliability

The baseline inspection program offered the client a clear understanding of equipment conditions at startup, enabling effective long-term integrity planning.
Automated work orders and inspection tracking in IDMS/CMMS enhanced asset lifecycle monitoring and data accuracy.

Sustainable Long-Term Integrity Management

Our handover of a fully developed integrity framework ensured that the client’s operations team had a self-sustaining system for managing RBI, dead leg assessments, and pressure system integrity.

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Asset Integrity Management Study for LNG Expansion Project in Asia

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