Boosting productivity through Alarm Rationalisation using Veracity APM

AIE created a tool that seamlessly connected with a Middle East based client’s existing DCS to the Veracity Cloud. All the extracted data from events were fed into the Alarm Rationaliser, which used a combination of Python and Image Recognition to convert the data into a common format. A natural language model then grouped the events together, and these events were ranked by the counts of events and cross-referenced with the equipment service. The analysis of data allowed actions to be raised, status reports to be generated, and corrective work orders to be raised in the operator’s Computerised Maintenance Management System (CMMS) or within Veracity Watchkeeping. As these actions got completed, the data was fed back to the Alarm Rationaliser via the Veracity interface for further analysis.

Chemical Optimization Insights with AIE's Multiplot Analysis

By the utilisation of AIE's multiplot feature on the analytics page of Veracity CCM, AIE's integrity and corrosion team in collaboration with the site team were capable of identifying increased general corrosion rates on the installed corrosion coupons in the production flowlines. With the help of multiplots, several parameters were trended against one another. After analysis, the increase in corrosion rate was attributed to the corrosion inhibitor changeover in addition to a lack of adherence to the dosages recommended from the third-party laboratory testing that was conducted. The first step towards optimisation has been identified to be an increase in chemical injection to meet the required target and a corresponding check on the extracted corrosion coupons and periodic inspections to assess the performance of the chemical. A failure to reduce the corrosion rates will trigger a corrosion inhibitor selection study to be initiated. This has helped demonstrate in a clear, concise and auditable manner the reasons behind chemical optimization decisions to senior management.

Leaders in Regulatory Compliance Assessments

AIE successfully implemented regulatory compliance assessments for a major Oil and Gas operators in North Africa in accordance with local and international standards. The scope included but was not limited to pressure systems, process safety, wells, HSE, operations and maintenance. Post completion of the assessment, AIE was also responsible for representing the client to the Regulatory Authority and to develop an integrated action plan for closure. AIE are currently responsible for managing the gaps closure phase whilst presenting the progress to the senior management of the organizations as well as to the Regulator. This works continues AIE’s established track record and reputation within the region and we are consistently recognised as a leader in this field.

Implementation of Reliability Centred Maintenance (RCM) process optimizes the maintenance program of a large-scale manufacturing plant

AIE was tasked with verifying, cleansing, and building an accurate Asset Register. The RCM analysis process was applied to each of the physical assets within the plant developing specific optimized maintenance strategies. Complying with RCM related international standards; AIE was able to fine tune planned maintenance strategies; reduce the maintenance of non-safety or non-production critical assets; to instead, increase the focus on value adding activities while aligning to the Plant business strategy and asset lifecycle phase. Linking criticality to Asset Register for improved reporting and deferral processes allowed the plant operator to focus efforts where they were most needed, reducing superfluous, non-value adding maintenance and driving down maintenance and spares holding costs.

Conducting Bowtie Operationalisation scope to a mature oil and gas client

Conducting bowtie risk assessments is a normal practice in the oil and gas industry, where a visual representation of potential hazards, their causes and the preventative and mitigative barriers aredeveloped and assessed. However, operationalizing these diagrams and utilizing them as a means to continuously measure and improve the effectiveness of an organization’s process safety management processes is a challenge. AIE was able to deliver a Bowtie Operationalization scope to a North African client wherein the bowtie diagrams were carefully designed to integrate with the client’s existing processes and systems and link to live critical data repositories such as the CMMS in use. This enabled the client to verify the health of each identified barrier on a daily basis, and in turn, to assess the effectiveness of managing each identified major accident hazard. Developing and operationalizing bowtie diagrams for a facility provided the organization with a key tool for understanding the overall status of their process safety management system and the steps required to improve it, clearing the way for accurate critical decision making and fostering a culture of proactive process safety and major accident hazard management.

An Onshore Gas plant enters phase of Mothballing and Preservation

AIE were selected as the key partner to prepare and advise in order for the Operator to select the optimum mothballing procedure. The key issues considered were as follows: The likely duration of the mothballing period; the value of the equipment and infrastructure to be mothballed; the maintenance requirements during mothballing (and the associated maintenance costs); the preservation methods to be deployed (and the associated costs of preservation); and the anticipated recommissioning time and the associated costs. Following the selection of the optimum strategy, AIE project managed the entire mothballing process and provided technical support on all aspects of the preservation, including the development of a preservation strategy. The facility, including subsea infrastructure, storage tanks, process equipment and major pipelines was successfully mothballed ontime and within budget, assisted in part by AIE carefully managing all contractors involved across the activities.

Reviving Pipeline Protection: AIE's Multiplot Success

By the utilisation of AIE's multiplot feature on the analytics page of Veracity CCM, AIE's integrity and corrosion team in collaboration with the site team were capable of identifying increased external metal loss towards the ends of the cathodically protected pipeline and a decrease in the level of protection across the years until the pipeline was deemed to be unprotected. With the help of multiplots, several parameters were trended against one another. After analysis, the lowest cathodic protection potentials were noted to be towards the ends of the pipeline. The lack of isolation flanges at the ends of the pipeline were identified to be the root cause. The site team and AIE collaboratively worked on revitalisation of the cathodic protection system through the installation of flanges, current demand tests and switch to an ICCP System from a sacrificial anode system utilising an existing transformer rectifier. The system is now operational at an optimised cost due to the utilisation of the existing transformer rectifier.