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Best practices for mechanical integrity system implementation MTBE facility case study

By: Description: 21 pDDC classification:
  • PD I116 2 0015550
Online resources: In: Summary: As part of a Petrochemical APM Project implementation, was conducted a particular Mechanical Integrity System assessment, which revealed a relevant gap on different issues of this function and represented significant contributor to low performance on Mechanical Integrity and Fixed Asset Reliability turning on negatively impact for the operation costs, equipment availability and production field factor. Poor performance around cost, effort, and a negative impact to production and maintenance got the attention of management, therefore was needed a plan to improve its Mechanical Integrity performance. Their goal was to reduce all these negative perception and impact and improve safety and profit. Based on APM (Asset Performance Management) Assessment was decided to proceed within an APM implementation project, which considered an implementation of a Mechanical Integrity System as one on main fixing solution. This part of project, starting within an performance assessment, which revealed a relevant gap in the program and represented significant contribution to low performing Mechanical Integrity and Fixed Asset Reliability negatively impacting the operation costs, equipment availability and production field factor. Using the expertise of the client around its Inspection, Process, Operation and Maintenance Departments we performed a series of activities to implement a Mechanical Integrity System that included RBI (Risk Based Inspection), Thickness Monitoring, Inspection Management, Integrity Operating Windows, Asset Integrity Strategies and Corrosion Control Principles. This allowed them to gain a complete understanding of their Asset Performance Management System. A petrochemical Mechanical Integrity system is based on systematic and continuous relationship between work process methods (functional) and technology platform (software) to achieve the appropriate identification, extension and analysis of each element that could trigger a deterioration mechanism. This approach is needed in order ensure the reliable performance throughout the life cycle of an asset and at same time ensure profitability and compliance of business needs. The key to success for this client’s implementation was the use of best practices to implement an effective Mechanical Integrity System. They started with almost nothing around Mechanical Integrity and moved where they were treating all threats proactively which allowed them to achieve real cost saving benefits of 1.6 MMUS$ through reduction of Turnaround Scope in less 1.5 years during implementation phase. As a result of this pilot study they were able to bolster their asset management by introducing a Mechanical Integrity Culture which changed their inspection activities to a predictive function from the reactive way they were used in the past.
Item type: Congresos (trabajos presentados)

As part of a Petrochemical APM Project implementation, was conducted a particular Mechanical Integrity System assessment, which revealed a relevant gap on different issues of this function and represented significant contributor to low performance on Mechanical Integrity and Fixed Asset Reliability turning on negatively impact for the operation costs, equipment availability and production field factor. Poor performance around cost, effort, and a negative impact to production and maintenance got the attention of management, therefore was needed a plan to improve its Mechanical Integrity performance. Their goal was to reduce all these negative perception and impact and improve safety and profit. Based on APM (Asset Performance Management) Assessment was decided to proceed within an APM implementation project, which considered an implementation of a Mechanical Integrity System as one on main fixing solution. This part of project, starting within an performance assessment, which revealed a relevant gap in the program and represented significant contribution to low performing Mechanical Integrity and Fixed Asset Reliability negatively impacting the operation costs, equipment availability and production field factor. Using the expertise of the client around its Inspection, Process, Operation and Maintenance Departments we performed a series of activities to implement a Mechanical Integrity System that included RBI (Risk Based Inspection), Thickness Monitoring, Inspection Management, Integrity Operating Windows, Asset Integrity Strategies and Corrosion Control Principles. This allowed them to gain a complete understanding of their Asset Performance Management System. A petrochemical Mechanical Integrity system is based on systematic and continuous relationship between work process methods (functional) and technology platform (software) to achieve the appropriate identification, extension and analysis of each element that could trigger a deterioration mechanism. This approach is needed in order ensure the reliable performance throughout the life cycle of an asset and at same time ensure profitability and compliance of business needs. The key to success for this client’s implementation was the use of best practices to implement an effective Mechanical Integrity System. They started with almost nothing around Mechanical Integrity and moved where they were treating all threats proactively which allowed them to achieve real cost saving benefits of 1.6 MMUS$ through reduction of Turnaround Scope in less 1.5 years during implementation phase. As a result of this pilot study they were able to bolster their asset management by introducing a Mechanical Integrity Culture which changed their inspection activities to a predictive function from the reactive way they were used in the past.



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