TO ACHIEVE YOUR INSPECTION, RELIABILITY & SAFETY GOALS

NEW PROJECT

Client Details Category Location

Qatar Petroleum DATA ACQUISITION AND RBI ANALYSES FOR NEW Asset Integrity Qatar
EQUIPMENT OF AGRP IN DUKHAN FIELDS

RECENTLY COMPLETED PROJECTS

Client Details Location

Qatar Petroleum Risk Based Inspection and Data Population for Piping Asset Integrity Qatar
Integrity Management System for NGL, Mesaieed
Qatar Petroleum Risk Insurance Engineering for Mesaieed Refinery Asset Integrity Qatar

info@iFluids.com
 Successfully implementing an AIM requires the right combination of design, engineering, and operational
integrity. iFluids partners with our clients to provide exactly the level of services they need. These services can
range from complete turn-key program design and implementation to simple gap-filling to complement a clients
existing AIM program.

The diagram below shows the scope of services which iFluids provides its clients.

info@iFluids.com
 What is Asset Integrity Management - AIM?

Asset integrity, or asset integrity management (AIM) is the term for an asset’s
capacity to run effectively and accurately, whilst also protecting the wellbeing
of all personnel and equipment with which it interacts – as well as the
measures in place to assure the asset’s life cycle. Asset integrity applies to the
entirety of an assets operation, from its design phase to its decommissioning
and replacement.

Operators need to maintain asset integrity to avoid unplanned downtime and

the associated safety and environmental incidents. Asset integrity
management (AIM) focuses on pressure containing vessels like pipes and tanks
to ensure that these assets deliver the required functions and performance in a
sustainable manner. These systems have been proven to drive down
inspection, maintenance and repair costs while improving plant reliability and
operational safety. AIM manages and mitigates deterioration caused by
corrosion and fatigue cracks.

The AIM market is primarily driven by increasing investment in the oil and gas
sector to meet the escalating global demand. Other leading industries for AIM
include refining, electrical power generation (like steam), and petro-chemical.

info@iFluids.com
 The constant business challenge for asset integrity managers is how to balance the designing,
maintenance, and replacement of assets throughout their life cycle with the costs to business – in terms
of finance, time, and resources. At its heart, it is the managing of the degradation of assets.

Elements of asset integrity management

Much of the oil and gas industry’s infrastructure is now either approaching or ageing far past its
operational life expectancy. With the cost of replacing assets, and the resultant turnaround time,
prohibitively high for so many facilities, asset integrity is now rivalling terms such as OPEX and Agile as
the watchword on people’s lips.

Challenges such as vessel inspection, which is a significant contributing factor to production downtime,
and corrosion under insulation, a frequent cause of sudden shutdowns, are on the rise – and taking the
step to employ new solutions is becoming a necessity in many sites, particularly those offshore.

The human element

Asset integrity is built on a belief that the majority of people within the company will do things properly,
and however optimistic that may sound, most of the time maintenance, inspection, and data
management is conducted with the best of intentions. However, things are often not completed
thoroughly or in as timely a manner as possible. Simple solutions like more frequent inspections won’t
necessarily scoop up every missed issue, nor will it engender a spirit of enthusiasm if workers are asked to
increase their inspection work, or implicated in faults that are missed.

info@iFluids.com
 Some signs that things may not all be well in the world of asset integrity management and inspection can include:
• Team members feel like any concerns they have about health and safety or the state of equipment are not
being taken seriously, leading to an environment in which faults are not even reported
• Any changes made to asset integrity plans, or even basic running of the facility, only occur after a large-scale
incident
• A lack of understanding around how to find root causes from simple fault reports, often resulting in people
being lulled into a false sense of security and overstating the level to which the facility is safe and operational
• There is a reliance on tacit understanding, rather than a tangible and easily-accessible set of rules surrounding
AIM and reporting faults
• There is a lowest-bidder attitude surrounding maintenance contractors, and knowledge of and enthusiasm for
asset integrity isn’t valued particularly highly

The very real result of this sort of climate is that nothing really happens. Asset integrity remains a barely tolerable
nuisance – a sort of roadblock to proper work, until a major incident forces a company to adapt, often at great
cost.

info@iFluids.com
 Plugging the gaps in asset integrity management systems

Whilst there are more AIM systems on the market than at any other point in the past, there
are still no out-of-the-box catch-all solutions. No inspection plan or database can deal with
all the AIM issues that can arise, but integrity systems are still seen as separate to the rest of
operations. Staff can be unwilling to take ownership of their responsibilities, instead seeing
the suite of various AIM packages as an attempt by the company to police them, rather than
an integral part of their role.

The gaps in AIM packages need to be filled with the vigilance of the very people they are
designed to protect, but a novel approach may be necessary to ensure this message is
heard.

info@iFluids.com
 RBI: Risk-Based Inspection

With ageing infrastructure fast becoming one of the industry’s major concerns, it is more important
than ever to make sure an effective system of identification is in place. Despite it sounding somewhat “Identifying
obvious, managing integrity, corrosion, and damage is like scoping out an iceberg from some distance damage
away.
conditions - and
For every easily-identifiable symptom of corrosion or asset instability, there are dozens of hidden the factors that
issues: hydrogen attack, high-temperature tempering, thermal fatigue, metallurgy issues, internal
system corrosion, and so on – and without dedicated and experienced professionals, implementing
alter them”
damage mitigation techniques is next to impossible. Once one has identified the need for thorough
inspection, the next step is to enact it.

RBI, or risk-based inspection is one such method – whereby one must balance risk reduction with the
minimum amount of effort required to streamline the process and free up more time. However, there
are a near-infinite number of ways in which to carry our maintenance – and with many risks (such as
calibration uncertainty or equipment accessibility) quantification is simply not possible. Therefore, each
company must decide how far along the quantitative/qualitative scale it sits; whether to rely more
heavily on experts, or statistics.

Depending on how well or badly a company nurtures its reliability culture, it will be operating in either
a reactive or a proactive manner. Needless to say, you want be proactive. Failure to anticipate and
monitor for hidden issues means you can only respond once problems have escalated, costing far more
in the long run, and rewarding those who are shown to be able to react quickly. Far from improving the
culture, this positive reinforcement further encourages reaction over action.
info@iFluids.com
 Application of Asset Integrity Management

AIM are used manage the capability of an asset to perform its required function throughout
the asset’s lifecycle. The systems help ensure that the people, systems, processes, and
resources that deliver integrity are in place, in use and will perform when required.

Asset integrity is managed at each stage of the asset lifecycle, including project design, asset
operation and decommissioning. Inspections, auditing/assurance and overall quality processes
are just some of the means to execute an effective integrity management program.

A program can include:

• Risk Based Inspection strategy
• Pipeline integrity management typically for corrosion
• In-service inspection with routine and specialist non-destructive testing
• Reliability centered maintenance (RCM)
• Condition-based maintenance
• Vibration induced fatigue failure solutions

info@iFluids.com
 Application of Asset Integrity Management

The AIM is used to maintain the asset in a fit-for-service condition while extending its
remaining life span in a reliable, safe and cost-effective manner. Internationally, AIM programs
are deployed to meet API-580, API-581, and PAS 55 requirements.

An asset integrity management system does not exist in isolation. To successfully implement an
asset integrity management system in a dynamic operating environment, it is essential that all
stakeholders have a consistent and a unified understanding of what the essentials of asset
integrity are and how they can be applied in their day-to-day operations, yet this is often cited
as among the most significant challenges in achieving an integrity culture within an
organization.

info@iFluids.com
 An asset has integrity when it is operated and maintained so that the combination of the
likelihood of failure and the consequence of failure makes the risk to people, to the
environment, and to the company as low as reasonably practical.

Plant integrity, safety, and reliability are major concerns to all plant operators and managers. The
primary objective of Asset Integrity Management (AIM) is to maintain the asset in a fit-for-
service condition while extending its remaining life in the most reliable, safe, and cost effective
manner.

In addition to regulatory and company requirements, operators of facilities and

pipelines have the following business needs
• Maximizing production
• Reducing lost income due to unplanned shutdowns
• Optimizing inspection and maintenance costs
• Maximizing asset value
• Maintaining an auditable system

Step 1 - Document Integrity Management Strategies and RBI Guidelines

Step 2 - Produce Integrity Management Procedures
Step 3 - Produce Performance Standards
Step 4 - Establish Integrity Management Database

info@iFluids.com
 PROGRAM DEVELOPMENT
iFluids has experience in developing and
documenting risk-based, time-based, and
condition-based inspection programs for
regions all over the world. Our programs meet
API-580, API-581, PAS 55 and other appropriate
requirements as applicable.
PROGRAM MANAGEMENT
iFluids has experienced project managers and
engineers who can oversee all aspects of the
project. Our personnel are also able to handle
the management of change process necessary
to transition from time-based or condition-
based to risk-based inspection programs.
info@iFluids.com
PROGRAM GAP ANALYSIS
iFluids experts assist our clients in identifying the gaps between their program
needs and current implementation.
iFluids understands the importance of insuring the availability of the real time
Key Performance Indicators (KPI) that are critical to successful programs.
RESOURCES TO IMPLEMENT THE PROGRAM
iFluids can participate in implementation at any level, from turn-key program
development and implementation to simple gap-filling services. Our inspectors are full-
time employees trained in our safety and quality methodologies. We provide a full
range of NDT services including advanced inspection techniques.
iFluids experts provide a comprehensive scope of fitness-for-service assessments
including determination of damage mechanisms. We can offer stand-alone CAD
drawing packages to support client-based or third-party inspection programs and
provide a unique set of value adding methodologies including data management
services, electronic document management, and field inspection data collection tools.
 Integrity Management System

This section attempts to outline some of the steps involved when establishing an Integrity Management System including Trend Analysis
and RBI.

This high-level process is generic and applicable to all static equipment classes, e.g. structures, (topside/underwater), process, pipelines,
subsea equipment and control systems.

Establishing an Asset Integrity Management System

1. Define the Asset Integrity Management Policies.
2. Define the High-Level Integrity Management Process.
3. Define the Asset scope, register, hierarchy, level, and boundaries.
4. List all failure threats applicable to each asset.
5. Define risk definitions and matrices - CoF , PoF , Risk Ranking, Confidence, etc.
6. Define mitigation strategies.
7. Define Roles and Responsibilities.
8. Define Trend Analysis and RBI processes.
9. Document Integrity Management Strategy and RBI Guidelines.
10. Produce Performance Standards.
11. Produce Integrity Management Procedures.
12. Establish Integrity Management software, database.
13. Maintain an ongoing Integrity Management Process.

info@iFluids.com
 Define Integrity Management Policies

The starting point is to define the Asset Integrity Management Policies. These are high-level goals
towards which the whole Asset Integrity Management (AIM) system is aimed.

Such AIM Policies may or may not already exist within a clients' management structure.

Below are typical examples of three IM Polices:

Asset Holders shall obtain

positive confirmation of
asset integrity status 'it is
not acceptable to be in the
dark about asset integrity
Actions to safeguard
status
technical integrity are non-
negotiable 'where a RED
condition exists, immediate
mitigating action is
0
mandatory'
Assets shall be maintained 'fit-
for-purpose' throughout their
operational life 'integrity
0
management is an ongoing
process that lasts throughout
the assets' life cycle'
info@iFluids.com
 Typical AIMS Framework
Development

info@iFluids.com
 Defining Asset Scope, Register, Hierarchy, Level and Boundaries

Asset Scope and Boundaries:

I. What are the static equipment (types and physical location) covered by the IM System and what are
their exact boundaries?

Asset Register and Hierarchy:

I. List of all the equipment and components within the scope of the IM System.
II. The level of detail should include the lowest inspection granularity. Typically individual valves and
anodes but not individual flanges and bolts. On piping, individual elbows and tees but not all fittings.

Asset Level:
I. Asset Level is an important concept which defines the level in the asset hierarchy at which RBI is carried
out; failure threats are allocated; Consequence and Probability of Failure are defined.
II. Guidance for the establishment of Asset Level can often be found in existing documents such as Safety
Cases.
III. Defining Asset Level too low leads to an unmanageable system: 'we don't do RBI for every nut and bolt'.
IV. Defining Asset Level too high leads to the Integrity Management System loosing its effectiveness, for
example, it would be ineffective to base RBI on Consequence of Failure defined for an entire offshore
complex.

info@iFluids.com
 Roles and Responsibilities in the Asset Integrity Management Process

•Definition of Roles and Responsibilities: Necessary for effective Integrity Management.

•Will vary depending on validity of Operators' existing management structure.
Below is an example:

info@iFluids.com
 RBI Concept

info@iFluids.com
 RBI Process, Inputs and Outputs

info@iFluids.com