Rigtech Independent Ltd. developed an Asset Integrity Monitoring system in order to address a number of technical and managerial deficiencies found during the audit of a clients offshore platform drilling installations.
The audit identified critical issues which needed addressing, including:
- The poor condition of structural elements (Derricks, Bulkheads, Decks, etc).
- The poor condition of HP pipework
- Corroded pressure vessels
- A lack of control of the integrity system which should have managed the issues above.
- A lack of planning by third party contractors tasked to make repairs.
- A lack of any sort of reporting system during repair activity.
- A failure in the management of change process.
- Failures in the maintenance system.
- No co-ordination of maintenance.
- No communication between the drilling contractor maintenance department and the operators integrity department.
- Maintenance being signed off but not having been done.
- Necessary repairs not documented, not planned, and hence a number of operational surprises due to equipment failures.
- Maintenance responsibilities not clearly defined.
- Electrical equipment in Hazardous areas not properly maintained.
- A lack of management control by the drilling contractor
- A failure to forward plan essential repair activity.
- Firefighting systems having been removed and not replaced.
- Firefighting systems signed off by a third party as having been maintained but clearly had not been.
- A lack of control of certification.
- A lack of control of essential inspections, lifting gear, critical gauges, pressure relief valves, etc.
ASSET INTEGRITY MONITORING SYSTEM
As a result of all these deficiencies, a need to improve performance and a drive towards cost saving, Rigtech set up an Asset Integrity Monitoring system.
The requirements of the system were to be:
- Easy to use.
- Accessible to everyone with an interest.
- Reliable and accurate on a continuous basis.
- A central source of information
- Able to maintain a track on project activity.
- Able to monitor activity in a number of areas such as Projects, Repair activity, Asset Integrity inspections, Drilling contractor maintenance.
To meet all these requirements, Rigtech set up an internet based system combining 3D image scanning coupled with a comprehensive database.
Read only access to the system is available to all involved parties through a personal unique log-in, whilst the content is secured by full read/write access to the system manager at Rigtech.
A brief outline of the system is as follows:
After entering their unique log in a user is faced with a home page that gives high level information and enables navigation to the rest of the site.
Alternatively a virtual tour of the platform can be piloted utilising 3 dimensional , 360 degree imagery.
The platform overview page offers several search and filter options for viewing all relevant information, documentation and imagery contained in each deficiency listed.
All data can be exported to Excel format spreadsheets if preferred
Documentation, certification, reports, photos etc. can all be accessed from the deficiency listing page
Data can be used to generate specific charts and graphs
The above graph reflects the huge reduction in the amount of platform deficiencies during a 2013 reactivation campaign, followed by a controlled level of the number of deficiencies. The pie charts reflect a much improved balance of the criticality of deficiencies.
The chart here shows the distribution of deficiencies by system
As a result of the Asset Integrity monitoring system being in place a number of significant achievements were made, as below:
- The MCDR deficiency reporting system came under tight control.
- The clients asset integrity system management was re-structured.
- Failing third party contractors were identified and contracts changed
- Records of Structural, HP pipe, Pressure vessel inspections, Project planning and maintenance activity became more accessible to all concerned.
- Maintenance and Repair work became a tightly planned activity.
- Start up and shut down maintenance was better defined.
- Work requirements and budgets could be assembled quicker.
- The number of MCDRs and repairs were substantially reduced and the criticality of outstanding items was significantly less.
- Through the use of the statistical and trending graphs, the client is able to demonstrate to the HSE that improvements are being made and their integrity management is a robust system.