CONSUB – ESDV Condition Monitoring

/in , , , /by

Problem Statement   

Client had identified performance issues with safety critical pipeline valves.

Aims

CONSUB undertook review of the safety critical valve operating data to identify root cause for performance issues and to identify solution to maximise safety critical valve availability

Method

A condition monitoring software platform was developed to analyse available SCADA data allowing safety critical valve performance trending to be established.

Impact

The development and implementation of the valve condition monitoring software platform allowed CONSUB’s valve specialist to trend the data and identify root cause for the safety critical valve performance. This allowed implementation of a condition based maintenance plan to coincide with planned shutdown.

The development of the condition monitoring platform also resulted in the implementation of a revised spares strategy that resulted in a significant reduction in repair durations for unplanned shutdowns of around 80% with an estimated saving of 360 days over the design life of the facilities.

Total Savings Anticipated 

360 days saved

Click on the image above to download the case study.

RINA – Reducing Maintenance Spend through Risk Based Inspection

/in , , , /by

Problem Statement 

Customer challenged to reduce plant OPEX without compromising safety and production efficiency. Currently spends $100k+ on critical system maintenance.

Aims

Implement Risk based inspection to reduce maintenance spend and ultimately reduce operating costs.

Method

Completed system assessment (materials, geometry, temp, flow, pressure etc).

Identified corrosion loops. Determined Probability and Consequence of Failure

Agreed risk classification with client

Updated recommended inspection frequency, location and technique

Impact

Reduced system maintenance cost by $46k annually

Validated engineering approach to industry standards to reduce risk (API 571/ 580)

Click on the image above to download the case study.

RINA – Asset Life Extension Through Reverification

/in , , , , /by

Problem Statement  

OEM recommended that gas turbine was at end of life based on operational history and needed to be retired from service, compromising viability of offshore facility.

Aims

  • Perform independent assessment of compressor/ turbine condition and residual life.

Method

  • Reviewed operation and maintenance record
  • Completed detailed assessment of asset including metallography
  • Reversed engineered 2 blades
  • FEA modelled steady state and transient loads

Impact

  • Verified design life at full and reduce loads
  • Validated 6 years continued operation
  • £5M capex avoidance
  • Mitigated premature CoP

Click on the image above to download the case study.