Know the Specific Reliability Needs for Each of Your Assets.

It's not uncommon for facilities to think that their assets are in good condition, then later realize there was significant damage which could have led to a failure. It's critical that a data-driven, analytical approach is taken to evaluate what is required for each asset to ensure its reliability and integrity.

Common Challenges We Help Solve

Unknown damage mechanisms impacting assets and CML locations that are not based on damage mechanisms

Inspection methodologies incorrectly looking for damage, including inspection plans that aren't optimized for maximum ROI

Maintenance strategies based on opinion and not data analysis

Lack of buy-in on equipment integrity strategies from operators

How We Solve These Challenges

Depending on your facility’s need, our team will utilize data to perform engineering analyses that enable improved asset strategies that are more effective at maintaining asset reliability. These methods will enable your facility to optimize your inspection and maintenance spend to focus holistically on facility availability, while maintaining integrity and function in critical assets. We develop the strategies by incorporating damage mechanism evaluation, Integrity Operating Windows (IOWs), and Reliability Centered Maintenance (RCM) to strategically approach asset health and reliability. These strategies will define the appropriate inspection and maintenance tasks to perform to optimize asset reliability.

There are a variety of methods and approaches that we utilize to determine the best holistic facility approach, including:

Identifying risks leading to loss of containment:

Damage and Corrosion Analysis and Models

We provide damage and corrosion analysis and models to identify the specific type of degradation and associated corrosion rate or susceptibility that is expected for each asset. Potential damage mechanisms, including historical and/or modeled rates and susceptibilities, are identified for each asset based on a systematic review of design, process, operation, and past inspections. By combining industry best practices (API 581, API 571, Compass Corrosion Guide, NACE standards, etc.) with our damage, corrosion, and metallurgical expertise, a theoretical model is produced that leads to improved inspections that track asset health.

Integrity Operating Windows

Integrity Operating Windows (IOWs) are limits and ranges placed on key process variables to make sure equipment integrity and safe operations are maintained. Keeping your facility’s complex processing equipment fully operational directly affects your bottom line. While predictive damage modeling is part of a robust asset integrity program, variable process or operating conditions (alternative containment levels, temperatures, pressures, etc.) have the potential to introduce new damage mechanisms or to accelerate damage mechanisms already predicted in the study. While operations need to be flexible to operate the unit to meet production’s needs, operating outside of the inspection department’s assumptions or prescriptions can accelerate the degradation of an asset and lead to unplanned loss of containment scenarios. Consequently, your facility may suffer from downtime and loss of production, which negatively affects funds and profitably. However, by maintaining your assets within prescribed operating conditions, you could reduce the risk of early failure. This can be accomplished through IOWs.

We help facilities proactively identify ranges and limits for key process variables in each unit by providing valuable operating guidance and parameters in which assets can optimally perform. By identifying potential damage mechanisms and critical integrity process variables across a unit, we determine acceptable upper and lower operating thresholds. These operating parameters are prioritized by criticality level (information, standard, or critical). We provide action recommendations with associated response times, ensuring that proper communication channels exist should those IOWs be breached.

Risk-Based Inspection Analysis (API 580/581)

Risk-Based Inspection (RBI) is an approach used to assign risk to particular assets within a facility, and then use that risk to prioritize and drive inspection strategies. We apply RBI theory in a systematic and standardized manner that provides objective assessments and repeatable results. We will help you select an appropriate RBI methodology and then execute that methodology through a regimented process of gathering documentation, mining critical data, predictive damage modeling, consequence of failure assessments, Inspection Data Management System (IDMS) integration, and RBI planning. As a result, facilities receive a set of optimized inspection strategies that efficiently target loss of containment risk.

Our RBI services will help you optimize your inspection strategies by enabling you to determine where to focus your inspection efforts, when to perform the inspections, and what methods to use for the greatest effectiveness. Overall, our approach helps facilities gain valuable insight into the condition of their assets so that data-driven decisions can be made, such as when to replace or repair an asset or when to recommend a design upgrade. By targeting areas of high risk and performing prescribed inspections, facilities are able to reduce unplanned failures, decrease overall loss of containment risk and increase the efficiency of their inspection programs.

Condition Monitoring Location (CML) and Thickness Monitoring Location (TML) Assignment and Optimization

CML optimization makes inspection efforts more efficient by focusing on areas where degradation is likely to occur to eliminate unnecessary CMLs that will not provide value. Our CML Optimization offering incorporates inspection history, corrosion expertise, and a statistical analysis to identify all susceptible damage mechanisms and where they are likely to occur. We are able to define the optimal extent, location, and technique needed to locate the damage, enabling effective inspections. The strategic placement enables inspectors to inspect and track degradation with repeatable precision that will feed into the appropriate system to track and make better decisions around planning for each asset’s end of life.

Inspection Testing, Planning, and Management (ITPM) Strategy Development

After determining an asset’s potential damage mechanisms, it’s important that the appropriate inspections are performed to verify and validate the asset’s condition and degradation over time. We work with stakeholders to align on appropriate inspection techniques that are capable to assess the current condition. Turnaround schedules, “in-lieu of” externals, and other constraints are evaluated to ensure the inspection plans optimize the inspection cost to maintain facility uptime and reduce additional costs during turnarounds.

Identifying risks leading to loss of function:

Failure Modes and Effects Analysis (FMEA)

Our criticality evaluation utilizes a streamlined Failure Modes and Effects Analysis (FMEA) or Failure Modes, Effects, and Criticality Analysis (FMECA). For each of the functions developed for the system, equipment failure modes are identified that could lead to a loss of the function. The overall effects of the equipment failure modes are then identified. Based on these effects, a determination is made as to the criticality of the equipment. If the failure cannot be tolerated in terms of the effect on the ability to meet performance objectives or other economic, safety, or environmental reasons, the equipment and failure mode is critical. If the effects can be tolerated or sufficiently mitigated, the equipment is non-critical.

We facilitate this session with critical site stakeholders to combine local and industry subject matter experts to ensure all failure modes are captured. During the discussion, justifications for equipment criticality are summarized for complete documentation. This structure assures agreement between all stakeholders on equipment criticality and enables strategic reliability-based proactive tasks to be developed.

Reliability Centered Maintenance (RCM)

Reliability Centered Maintenance (RCM) delivers a set of reliability-based, proactive tasks, focused on sustaining functionality of systems and equipment. Our RCM approach directly facilitates scheduling and planning tasks so that a clear, concise priority can be assigned to proactive maintenance and corrective tasks. The approach also identifies cost benefits for allowing low-risk equipment to run to failure due to the low economic, safety and/or environmental impact. In return, the process yields a maintenance program with the lowest base (proactive and reactive) cost that produces results that exceed the effectiveness of other more resource-intensive processes.

Our RCM process involves key client personnel who have a history with the systems and equipment under analysis. In coordination with your facility, we can generate reliability-based maintenance strategies and implement them into relevant Computerized Maintenance Management Systems (CMMS) and Enterprise Asset Management (EAM) systems to ensure programs are delivered on schedule, evergreened, and within budget. In addition, our experts provide hands-on training to end users to make sure the RCM skill set is embedded in your facility's processes and systems. Our approach to RCM enables significant resource savings, compared to the “classic RCM” process developed for the power and process industries, requiring less investment from you while maintaining appropriate technical rigor.

Contact Us to Assess Your Asset Strategy