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Oil and gas industry interest is surging in using remote survey technologies for more cost-efficient, safer, and lower-carbon certification, verification, and inspection of assets and operations. Amid COVID-19 travel restrictions in 2020, DNV GL has conducted more than 4,000 remote surveys for the sector. These have provided the supply chain with the assurance it needs to keep projects and operations running safely and on schedule. Remote surveys involve fixed and mobile cameras (e.g., smartphones) giving customers instant access to DNV GL experts worldwide for verification, classification, and certification of assets, verification of materials and components, inspection, and marine assurance. The growing track record for remote survey technology could soon make it the method of choice for inspections in some places and circumstances, according to a senior expert at one leading oil and gas exploration and production company.
Industrial robots are becoming an increasingly popular choice in a variety of industries for different applications. Going by responses to a McKinsey and Company survey, up to 88% of businesses worldwide intend to adopt robotic automation into their infrastructure. Modern robotic units are highly programmable and versatile, and they come in a wide range of models ideal for plant floor activities, from quality control to product assembling and warehousing. However, apart from the manufacturing process, there are other applications for robots: in the maintenance department. Keeping systems and equipment continuously running in peak condition requires a strategic mix of planning and scheduling as well as adequate allocation of resources.
Pressure vessels used in the petrochemical industry inspected manually by people working inside the vessels, which is a very time consuming operation in a potentially
ADNOC CEO has launched Oil & Gas 4.0 in the year 2019 and stated that Oil and Gas 4.0 means rethinking how our industry adopts and applies technology, connects with non-traditional partners, shows environmental leadership and most importantly attracts and retains talent. We as, ADNOC Gas Processing Technical Services Engineering division inspired by the ADNOC CEO's speech and adopted introduction of innovative technology in every sphere of technical field. We choose to explore the possiblitity of the introduction of drones, robotics and other technology that are increasing efficiency and productivity while protecting the environment in all stages of energy production.
ADNOC Gas Processing has conducted Corrosion and Inspection forum in 2019 as a part of digitasation by inviting leaders in the NDT field to show cause the available latest technology. During the forum, we could explore several advanced NDT techniques including Drones, robotics, helmet mounted cameras and wireless UT thikness monitoing devices. With the advancement of technology, drones once predominantly used for patrolling highways and delivery of the foods were used extensively for visual inspection of elevated structures (stacks) and robotics are used to inspection pressure vessels and storage tanks with out necessity of man entry and thus avaiding the human exposure to the hazdous evironments.
Asset Performance Management (APM) aims to improve the reliability and availability of physical assets while minimizing risks and operating costs, optimizing productivity to increase return on asset investment. Traditional APM combines IT data and OT data with big data analytics to define a course of action that will improve business outcomes.
This paper introduces a new concept for APM, Visual Asset Performance Management (Visual APM), that adds an asset information layer to APM. A Visual APM solution uses navigable 2D and 3D models to deliver "living" digital twins of equipment, machinery, and processes. It creates a centralized information repository to provide a seamless, contextualized view of data.
This approach integrates interactive visualizations of equipment and plants with real-time data and analytics that teams can leverage to inspect asset health and monitor business performance in real time.
Visual APM represents a paradigm shift for conventional Asset Performance Management, presenting a new way for engineers, operators, and maintenance teams to interact with asset information throughout its entire life cycle to reduce CAPEX and OPEX. The ability to quickly access asset and plant information and visualize asset performance can help increase the overall health of a facility significantly.
A top 10 Oil & Gas company that has adopted this approach achieved the following results:
Cut maintenance costs such as corrosion under insulation by 10–20% Shortened the time spent in the planning inspections process by up to 60% while improving the quality of the planning Achieved overall improvement in the effectiveness of campaigns and minimized rework Reduced health, safety, and environmental hazards Digitized the input of inspection results through handheld devices Increased the accuracy of data captures in the field Enhanced reporting capabilities
Cut maintenance costs such as corrosion under insulation by 10–20%
Shortened the time spent in the planning inspections process by up to 60% while improving the quality of the planning
Achieved overall improvement in the effectiveness of campaigns and minimized rework
Reduced health, safety, and environmental hazards
Digitized the input of inspection results through handheld devices
Increased the accuracy of data captures in the field
Enhanced reporting capabilities
ADNOC LNG natural gas export facilities (five Gas turbines driving centrifugal compressors) had experienced blade parts liberation at the first row of blades because of Chlorine and Sulphur presence in air intake system. The objective is to identify all integrity risks and to implement advanced technical enhancements to restore critical gas turbines integrity.
ADNOC LNG team carried out Root Cause Analysis (RCA) study and investigation as per existing procedures. Team collected all the events and engaged turbine manufacturer to identify root cause through intensive analysis and studies. Also engaged metallurgical third part lab to identify the nature of encountered cracks and type of fractions. The investigation had the scope to identify the origination point of blade liberation studying the broken surfaces of the blades. From the metallurgical point of view, thorugh metal strucuture studies and magnifications of broken surfaces, it was seen a series of point where metal structure changed from its original composition, having a consequent drop in properties like strength. Furthermore, the broken surfaces was typical of a metal subjected to a constast stress. RCA concluded that gas turbine had suffered of Axial Compressor Blade Stress Corrosion. The major action plan to be implemented on fast track was to replace rotors with coated blades, then rest of RCA actions were applied. The implementations and enhancements are fulfilled jointly by ADNOC LNG and manufacturer successfully.
Main implementations are blade coating, upgrade of air filter elements and blades tip clearance optimization. The recommended enhancements were implemented and successfully arrested the risk of blades liberation to assure gas turbine integrity and sustainable gas export revenues. ADNOC LNG has successfully upgraded all axial compressors rotors and eliminated the risk of blades failure. Since applied enhancements, no further blades failure encountered confirming sustainable operations and integrity assurance. The same successful enhancements were also implemented at ADNOC LNG utilities gas turbines generator sets.
The aim of the abstract is to share and focus on success story of gas turbine integrity enhancements and improvements to assure gas export sustainability. Furthermore, it wants to draw reader attention to potential hidden issues that cannot be discovered during turbine operation in order to prevente major damages resulting in losing of turbine and production.
Techasirithaworn, Mittrapa (Mubadala Petroleum Thailand) | Tachavarakul, Vichai (Mubadala Petroleum Thailand) | Krittaphol, Nuttawut (Mubadala Petroleum Thailand) | Grassian, David (Mubadala Petroleum)
Aging facilities are a common issue within the oil and gas industry. This research demonstrates a practical approach to aging life extension, taking into account risks and constraints, such as budgets, resources and offshore field-level logistics. The case study reviewed is Mubadala Petroleum's (MPs) small, but aging, upstream offshore oil facility located in the Gulf of Thailand, known as the Jasmine/BanYen field. The field includes six offshore platforms, subsea pipelines and a Floating Production, Storage and Offloading asset (FPSO). The field, which commenced production in 2005, was initially expected to have a relatively short field life, and as a result, the facilities were genially specified for only a 10-year lifespan. As the field exceeded expectations in term of volumes and longevity, it became clear to MP management that a practical and cost effective life extension plan was necessary. As such, this research describes the approach to taken by MP to extend the life of the Jasmine/BanYen facilities.
The approach taken by MP was closely aligned with the recommendations and best practices proposed by several regulatory authorities with extensive experience in managing aging offshore oil and gas facilities, such as the United Kingdom's (UK) Health and Safety Executive (HSE) and the Norwegian Petroleum Safety Authority (PSA). As such, the facilities were first functionally decomposed into a number of subsystems, such as Wells, Structures, Pipelines, Topsides, Risers and Floating Assets. A target life extension period was specified, which was followed by a series of focused risk assessments to determine the levels of risk expected during the life extension period, with the critical gaps identified. Each risk assessment involved specialist resources related to the subsystem under review, such as structural engineers, process engineers, marine engineers, instrument engineers, as well as technical safety and environmental engineers. For any risks that were deemed unacceptable, a mitigation plan was suggested and associated costs developed. Finally, a phased master plan was developed that took into account constraints while prioritizing actions based on the determined risk levels.
The implementation of the plan was challenged by the intricacies of offshore logistics, including constraints on supply boats, Persons On Board (POB) etc., and budgetary constraints, which were considerable given the relatively high operational expenses of the field and the low oil price environment. As per the risk assessment, high priority activities were determined to be with respect to FPSO, well integrity and the integrity of subsea pipelines. The platform structures and topsides were considered to be lower priority, as they had already been verified for the life extension period by the company's Asset Integrity (AI) program. Additionally, MP also has a robust Safety Critical Element (SCE) system in place which is an integral part of the AI program, and as such there were no unexpected revelations with regards to the condition of the SCEs. Obsolescence was determined to be a low priority since the equipment on the platforms are relatively new, and most of the Original Equipment Manufacturers (OEMs) provided assurance on the availability of spare parts for the main equipment items.
Highlights of the life extension plan are as follows: Production flexible riser connecting the steel pipeline network to the FPSO has been replaced Pipelines inspections are ongoing, and repairs are being prioritized The design life of platform subsea structures has been extended based on fatigue analysis Subsidence analysis has been carried out on all platforms and indicated no major anomalies Platform power generation facilities are progressively being upgraded A comprehensive well integrity systems have been implemented and critical activities such as barrier testing and well repairs are being carried out regularly Repairs to the hull of the FPSO have been carried out
Production flexible riser connecting the steel pipeline network to the FPSO has been replaced
Pipelines inspections are ongoing, and repairs are being prioritized
The design life of platform subsea structures has been extended based on fatigue analysis
Subsidence analysis has been carried out on all platforms and indicated no major anomalies
Platform power generation facilities are progressively being upgraded
A comprehensive well integrity systems have been implemented and critical activities such as barrier testing and well repairs are being carried out regularly
Repairs to the hull of the FPSO have been carried out
In a marginal and aging asset, ensuring the pipeline integrity plays an important role in order to maintain fluid transmission. Shutting off a single pipeline could jeopardize the overall asset operation. This paper presents a methodology for the identification, assessment and mitigation of dragged submerged pipelines.
As part of Pipeline Integrity Management, the inspection of an anchor-dragged submerged pipeline was carried out with the aid of a Remotely Operated Vehicle (ROV) equipped with pipe-tracker module. This enabled us to determine the extent of the pipeline alignment deviation, as well as to conduct a close visual inspection of the pipeline. With the information retrieved from the inspection, a fit-for-purpose pipeline drag analysis was performed to assess the pipeline integrity. The pipeline was simulated using the Finite Element Analysis (FEA) methodology which considered various axial and lateral soil friction factors to achieve the closest approximation of the pipeline's actual condition. Once the best-fit parameters were determined, code checks were performed in accordance with the DNVGL-ST-F101 [
As capital projects execution is increasingly transformed through digitalisation, there are further opportunities to optimise the efficiencies and effectiveness of Engineering, Procurement, and Construction (EPC) phase maintenance, and integrity management programme development. This paper presents a model for the development of lifecycle maintenance and integrity management programmes during the EPC phase. The approach comprises a fully integrated solution for all required work scopes. This model is embedded within an asset management build platform and has been designed to encourage collaborative working and maximise efficiencies during execution.
The approach enables the provision of clear information to the EPC project team highlighting the critical path data requirements and schedules. This provides enhanced definition of Computerised Maintenance Management System (CMMS) build processes, smoother project management, improved consistency and accuracy of the asset register, hierarchy build, materials, inventory content and linkages. Requirements for manual data scraping from engineering drawings, datasheets and vendor documentation have been substantially reduced. Instead, the approach maximises opportunities to standardise and digitise much of data handling and capture required for successful programme development.
The model incorporates simple, robust rulesets for lifecycle maintenance and integrity management strategies, which consider aspects such as: class code, equipment sub-categories, materials, and operating context. This has resulted in consistent, standardised programme development and implementation, while accounting for owner/operator specifications and requirements. Furthermore, the data deliverables and outputs can be used as a basis for CMMS management of change during the subsequent operating phase.
A critical challenge facing the integrity of many assets throughout the oil and gas industry is directly related to corrosion under insulation (CUI). Unfortunately, the lack of adequate inspection technologies adds to this well-known industrial challenge. Presented in this paper is an inspection tool enhanced using Artificial Intelligence (AI) that can provide field inspection engineers with a facility heat map of insulated asset integrity allowing inspection prioritization.
The approach used in this research, and presented here, was to enhance the output of already known and field approved thermographic technologies using a purpose built AI based on Machine Learning (ML). By examining the progression of thermal images, captured over time (<20 minutes), corrosion and factors that cause this degradation are predicted by extracting thermal anomaly features and correlating them with corrosion and irregularities in the structural integrity of assets verified visually during the initial learning phase of the ML algorithm. Additional benefits to this technique include enhanced safety through remote inspection and additional cost savings from monitoring assets online.
To develop and verify the CUI technology results from in-house laboratory tests followed by field validation outcomes will be presented. Laboratory trials were carried out using a series of insulated field assets with different levels of degradation and structural integrity set up to mimic the thermal behavior of in-process assets. This initial feasibility study allowed the definition of key parameters required to build an effective ML model. Following in-house trials a series of field tests and visual verification was performed on both hot and cold insulated assets to gather a sufficient amount of datasets to train the predictive algorithm. To enhance this learning process, synthetic data was created based on real field asset configurations and operating parameters. Finally, during the technology validation phase, again on field assets, the AI technique coupled with a commercial field approved thermographic camera returned a predictive accuracy in the range of 85 – 90%.
The work presented in this paper provides a solution for the current lack of technologies to monitor the presence of CUI by enabling and enhancing the output from already known and field approved technologies, such as thermography, using AI. Additional benefits of this approach include safety enhancement through non-contact online inspection and cost savings by reducing the complexity of asset preparation (scaffolding) and downtime.
Medagoda, Lashika (Abyss Solutions Ptd Ltd) | Jolly, Jordan (Abyss Solutions Ptd Ltd) | Bargoti, Suchet (Abyss Solutions Ptd Ltd) | Kazzaz, Abraham (Abyss Solutions Ptd Ltd) | Khan, Junaid (Abyss Solutions Ptd Ltd) | Morgan, Hamish (Abyss Solutions Ptd Ltd) | Altamimi, Waleed (Tasneef Maritime) | Ahsan, Nasir (Abyss Solutions Ptd Ltd) | Naqshbandi, Masood (Abyss Solutions Ptd Ltd)
Inspection of underwater assets on oil and gas offshore platforms are required to assess asset integrity, and whether intervention is required. These assets include mooring chains, fairleads, anodes and ballast tanks. Typically, calipers are used for taking measurements of these objects. Limitations of this technique include inaccuracy, inefficiency and potential damage to the asset. Compact underwater camera systems, including imaging sensors and lighting, are proposed to solve limitations of caliper measurements. Data processing creates scaled 3D models for measurement analysis and automatic fault detection. This paper presents Lantern Eye-S, a stereo-based visual measurement system developed by the authors. It is a stereo imaging system, which includes a stereo camera pair linked to a set of underwater strobes. It is extremely compact and can be deployed on very small ROVs, down to the 30kg class. Results are available as quickly as 5 minutes for in-situ analysis and assessment. Final results are available in 8 hours for detailed inspection. Calibration accounts for the water environment the images are taken, primarily to account for salinity in the water. Measurements can be automatically extracted, and comparisons are made to as-built drawings. Validation of the measurement is also undertaken with a known ground truth object placed in the water, to ensure integrity in the measurement.
Results include offshore integration and deployment on a mini-ROV (30kg class) and working class ROV (multiple tons). An important result from this work is that calipers were found to typically overestimate dimensions on mooring chain diameters. High accuracy measurements of small objects, with a compact camera system, was shown to be possible with the work in this paper. The use of a novel validation apparatus and uncertainty analysis allows appropriate levels of confidence to be attributed to the acquired analytics.