Übersicht
A major operator is using our Inform Risk-based Inspection (RBI) software to optimize the inspection and integrity management of pressure systems at one of their onshore oil and gas processing facilities.
The RBI software manages data and risk profiles for more than 350 assets, providing the client with an auditable and transparent method of demonstrating compliance and the safe working condition of their assets. Our team has successfully used the software to reduce costs and maximize uptime by extending inspection intervals, shortening shutdown durations, and improving the safety and reliability of their operations.
3+ Years
Customer use of the most recent version of the RBI software.
35% of Intervals Extended
Equipment inspection intervals extended for more than a third of the plant.
38% Reduction in Confined Space Entry
Confined space vessel entry reduced by 38% with the introduction of RBI for in-service inspection.
Herausforderung
The client was interested in addressing a number of challenges that prevented them from optimizing their inspection programs. Our team of engineers ensured each of these was addressed and focused on delivering a software platform that met the client’s objectives.
These challenges included:
- Time-Based Inspection Intervals: These intervals are conservative and do not allow for either targeting high-risk items or reduction of wasted effort on areas of low risk. Such inspection programs are expensive, deliver low value, and do not provide visibility of risk profile.
- Creating an RBI Methodology and Improving Data Transparency: The facility had no methodology on which to base an RBI program. They did not have the internal expertise or bandwidth to develop a system that would provide them with the transparency, insight, and configurability they desired. In addition, the client did not have extensive data for implementation of a quantitative RBI or any available prescribed methodology. They did, however, require evidence of compliance to an accepted approach.
- Establishing Auditable and Traceable Evidence of Compliance: The client wanted a better method for demonstrating compliance to regulators. Their past approach was opaque, labor intensive, and did not provide the data needed to substantiate decision making. They needed something transparent, easy to access, and auditable to confirm their assets were safe for operations and to confirm their methodology was acceptable to the regulator.
Unsere Lösung
We developed and integrated a comprehensive RBI approach to ensure inspection intervals were adopted based on risk, not prescriptive time scales.
As part of the scope, our engineers provided key deliverables including methodology and logic development, establishing risk profiles, and evergreening capabilities alongside their full project support.
We used the client’s existing limited data, collected over the assets’ operational life, to generate a methodology and logic that could be replicated in the software. The software interface provided the client with an expedited and data-driven solution. They were able to show regulators the information being used to determine their inspection interval outputs. This resulted in a substantiated move from a prescriptive to proactive inspection program.
Our engineers designed the system to support evergreening with every inspection interval or as new inspection data was ready for input into the software, keeping the information and insights being used for decision-making live and available for consumption or reporting. The software was designed to be flexible and configurable, enabling modifications to damage mechanisms, equipment operating conditions, and other factors that may affect risk profiles.
An additional attribute of the RBI software is its filtering and grouping functionality. Its ability to support the scheduling of optimized inspection campaigns by using the platform to identify damage mechanisms common between assets was an essential component to transforming inspection planning and overall operational efficiency.
Ergebnisse
The client has realized substantial benefits over the course of more than 15 years of using our RBI approach. Cost savings, fewer mobilizations of personnel and inspection equipment, increased uptime, demonstrating compliance, and overall operational efficiency have played key roles in the client’s decision to continue using our RBI software as their preferred solution.
- Extended Inspection Intervals: The first iterations resulted in statutory intervals being extended for 35% of the system’s plant and equipment.
- Shortened Shutdown Duration and Improved Inspection Planning: We have enabled the client to realize significant cost savings based on the software’s ability to group asset types and features, damage mechanisms, risk profiles, and operating conditions. This facilitates optimization of inspection planning and scheduled inspections. The RBI software is pivotal to shortening shutdown windows by identifying assets that can be inspected while in-service, without confined space entry, and those that can safely be deferred to a later date.
- Improved Safety Outcomes: Through the introduction of the approach, a 20% reduction in CSE was delivered on the first iteration. There was a significant positive impact to safety risk profile.
- Reduced Engineering Load: The introduction of the RBI software significantly reduced the client's internal engineering load previously dedicated to the activities the platform can automate. They have reallocated resources to value-adding work scopes, improving overall operational efficiency and expenditure.
- Improved Data Interrogation: Our engineers are able to use their extensive experience and expertise in RBI methodology and logic development to provide a better interrogation of the client’s systems as a whole. This was underpinned by a a thorough understanding of the required data and inputs.
- Visualization of Risk Exposure: The software platform provides a method of easily visualizing risk profiles and securely sharing them with relevant stakeholders for improved oversight and decision making.
- Configurable Reporting: The software supports configurable reporting, making plant inspection compliance status easily demonstrable to regulators.
Oceaneering’s RBI tool has proven its value, transforming the client’s inspection approach and improving their operational expenditure and insight. The solution is applicable across asset types and industries and is ideal for operators interested in leveraging RBI to make data-driven decisions, enhance operational efficiency, and ensure the safety, longevity, and reliability of their equipment.
Ready to adopt a more structured, data-driven approach to inspection and asset integrity management?
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