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Maximizing Asset Integrity & Operational Efficiency: Lessons Learned From Real-World Projects

24 May

In today’s dynamic industrial landscape, asset assurance and operational efficiency are paramount for organisations across various sectors The benefits of a systematic and technologically enabled Asset Management System are wide-ranging, providing tangible benefits for industrial facilities.

Asset Integrity Engineering (AIE) has recently completed two notable projects, delivered using our proprietary asset integrity management and operational gap assessment framework. Aimed at supporting the core tenants of asset management, we partner with owners/operators to baseline their management processes and develop a roadmap to achieve operational excellence. In this article, we delve into these projects to understand how our advisory approach can be leveraged to add value in the Power & Utilities sector.

Project 1

AIE was contracted by a Power and Utilities company to carry out a technical due diligence assessment of their Power & Desalination plant. This was required to provide a baseline for the transition from a Fixed Price O&M Agreement to an open book Cost Pass Through (CPT) model. Our client required assurance that the scheduled maintenance activities had been carried out in line with the maintenance strategy and OEM recommendations, throughout the fixed price period. Plus developing the baseline condition of all plant/equipment relative to the age of the facility.

AIE commended the leadership commitment and organisational culture, whilst highlighting the need for a holistic asset integrity management framework. Recommendations included developing a corporate Asset Integrity Management Framework and specific competency assessments for critical positions. The assessment also identified areas of deficiency in maintenance execution, which amounted to around $8 million of activities not conducted during the fixed price period and a number of temporary repairs which required rectification under the new O&M agreement.

Project 2

AIE was engaged to perform an asset integrity management system gap assessment for their smelter operations in the UAE. The assessment covered various aspects, including equipment-specific integrity, maintenance history, and management processes. Across a varied plant landscape ranging from high-hazard mechanical handling and pot line areas, through to more conventional captive power units and their balance of plant.

AIE recognized the organisation’s maturity in management systems but emphasized the need for a comprehensive asset integrity management framework. Recommendations focused on developing risk-based integrity planning, enhancing organisational structures, and improving the execution of integrity management activities which were key to maintaining process safety.

Both projects followed our rigorous assessment process, including desktop reviews, site visits, interviews, and element scoring. AIE evaluated key integrity elements and management processes to develop a baseline which can identify gaps and areas for improvement.

The experiences gained from both projects offer valuable insights for the Power & Utilities sector which can be applied at any stage in the asset lifecycle. Implementing a holistic asset management framework, adopting risk-based integrity planning, and enhancing organisational structures can significantly improve asset reliability, safety, and operational efficiency.

By leveraging the lessons learned from these projects, organisations can proactively address operational gaps, optimise asset performance and ensure safe and reliable operations.

Connect with AIE’s expert team to learn more about our comprehensive asset integrity engineering services and how we can help maximise asset life and ensure safe operations.


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