The Necessity of Asset Integrity Management for the Petrochemical Sector

Posted on Mar 29, 2024 | by Metegrity Inc. | Category: Asset Integrity Management, Petrochemical, Integrity Operating Windows, Visions Enterprise

The Petrochemical industry has a deep understanding of the intricate challenges of asset integrity management. Owner operators within this sector typically oversee a diverse range of equipment types, materials, and processes, often more varied than those in the Oil & Gas sector. Additionally, Petrochemical companies operate within a heightened risk landscape, encompassing safety and environmental mishaps such as loss of containment, resulting in toxic and flammable chemical releases, all stemming from the inherent properties of the materials involved.

The financial toll of such catastrophes is apparent, including repair costs, replacements, business interruptions, business reputation, and cleanup. Equally concerning are the environmental impacts and safety hazards to personnel. Additionally, temperature extremes resulting from fire or explosion may require adjacent equipment to be assessed to confirm that upper temperature limits were not exceeded.

The intricate and diverse equipment and materials used in the Petrochemical sector often lead owner operators to make a common mistake: assuming that their processes are too complex for a standard Asset Integrity Management (AIM) program. Consequently, they may opt to solely rely on Enterprise Resource Planning software (ERP) to oversee their assets and operations. Alternatively, faced with numerous AIM solutions, companies may hesitate to commit and continue relying solely on their existing ERP. While ERPs have their advantages within their designated functions, they alone are insufficient in accurately applying and mitigating risks or preventing unplanned shutdowns or disasters. This short-term fix may create the illusion of proper asset management, but it is typically indefensible during audits following incidents.

The solution lies in adopting a comprehensive Asset Integrity Management (AIM) program specifically tailored to the diverse equipment, materials, and processes inherent in the petrochemical industry, seamlessly integrating with existing ERP systems. This approach ensures thorough assessment, monitoring, and risk mitigation for all plant equipment.

When selecting such a program, it is crucial to verify its ability to manage various equipment types comprehensively, from reactors to vessels, pumps, and other processing equipment. It should demonstrate a proven track record in all aspects of petrochemical asset integrity management, from feedstock in (ethane, propane, naphtha, etc.) to finished product out (polystyrenes, polymers, olefins, ethylene's). Additionally, the program should be adaptable to different manufacturing processes - upstream, midstream, or downstream and configurable to accommodate each process's unique properties, with robust corrosion and thickness monitoring capabilities to address the industry's heightened corrosion risks.

Key considerations also include leveraging Integrity Operating Windows to measure operating conditions in real-time, such as temperature limits and pressure boundaries, to certify equipment is operating within design and/or integrity limits, regulatory compliance with standards such as API (esp. 580/579), OSHA, and ISO, and facilitate seamless integration with existing ERP systems. The ability to embed relevant documents, photos, and drawings is essential for comprehensive asset integrity management.

By addressing these aspects, companies can significantly reduce environmental impact, enhance personnel safety, and minimize costly failures, improving ROI. Benefits include:

• Easier adherence to industry regulations
• Proactive inspection and maintenance to extend equipment life
• Streamlined organization of records (inspections, tests, and recommendations) for accurate risk identification and damage mechanism.
• More accurate retention of failure analyses and corrosion investigations resulting in a greater understanding of corrosion rates and use of chemical injection inhibitors
• Fine-tuned inspection/maintenance/repair & replacement processes
• Expert through-life support