Asset integrity services such as KBAI™ (Knowledge Based Asset Integrity) provide risk profiling for key components based on assessment of data from a variety of sources. This allows owners and operators to better predict where problems will occur. Similar approaches are already regularly used by owners and operators in other industries such as oil and gas. Such systems provide a maintenance and/or inspection task plan that is optimised specifically for the asset and the business. - See more at: http://blog.lr.org/2013/05/kbai-the-definitive-addition-to-your-om-strategy/#sthash.TWKPtbTK.dpuf
1. Lloyd’s Register Energy
Knowledge Based Asset Integrity (KBAI) for wind farms
Andrew Martin
Technical Manager
Lloyd’s Register Energy
Working together
for a safer world
2. Lloyd’s Register Energy
Knowledge Based Asset Integrity (KBAI)
(events per year)
•Equipment type and items used
•Age, usage, environment, etc
•Equipment condition (based on
visual inspection, past
maintenance, failure causes and
condition monitoring, etc)
1
Probability Ranking
Likelihood of failure
HIGH
2
MED HIGH
(£ impact per event)
MEDIUM
3
4
Maintenance and inspection
task plan optimised to the asset
and the business
•Includes industry best practices
•May increase or decrease current
maintenance
LOW
5
E
D
C
B
A
Consequence ranking
Consequence of failure
(impact per event)
Lloyd’s Register Energy
•Disruption to business
•Environmental + health and safety impacts
•Reputation – public/political
3. Lloyd’s Register Energy
Why this approach?
•
Improves reliability
•
Consequential loss reduction - increasing
exported electrical power
•
Provides justification for:
•
•
Actions to reduce breakdowns such as
prioritising replacements
•
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Establishing the correct level of
maintenance and hence maintenance
expenditure
Integrity measurements for additional
failure modes to give further
confidence in asset condition
4. Lloyd’s Register Energy
Case study – port cranes
•
Breakdown duration reduced
•
Quay Side crane (QS) ‐24%;
•
Rubber Tyred Gantry cranes (RTG) ‐
12%
•
Maintenance cost savings: QS 17%; RTG
32%
•
Significant commercial operational benefits:
•
Crane efficiency enhanced
•
Containers handled and related safety
all improved
•
Ship turnaround and throughput
improved
Lloyd’s Register Energy
5. Lloyd’s Register Energy
Case study – oil refinery piping
•
Pilot study on fixed equipment on eight
process units led to $1.5m in
turnaround cost savings and $7m in
risk reduction
•
Rolled out to 6 further refineries
resulting in over $160m in risk
reduction and on-going savings in
turnaround plans. Achieved within 3
years.
•
Key lesson learned is the need to
continually audit and manage the
system to ensure the alignment of
people processes and technology
Identifying the DELIVERED RISK
REDUCTIO N VALUE
Finding t his CUI problem w as
est imat ed t o save t he ref iner $2M M .
An addit ional $4M M in lost
product ion w as avoided w hen RBM I
ident if ied exchanger problems bef ore
t hey could af f ect t he saf e operat ion of
t he ref inery. This added up t o over
$6.373 M M in reduced risk all w it hin 3
mont hs of complet ing t he project .
RBM I - RELIABILITY BASED M ECHANICAL INTEGRITY
Achieving Value
The small branch connection on the line was found to be corroded nearly
through-wall. Continued operation without finding and repairing the damaged
connection would have resulted in a failure with potentially serious effect.
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7. Configuration: Risk units & probability factors are identified
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for each asset type
Risk Units
Probability Factors
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9. The prediction for next year shows criticality has changed for five
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risk units – undertake pre-emptive work on these
Date for
criticality
calculation
Criticality
change
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10. Lloyd’s Register Energy
Summary
•
Capture relevant data to make informed
decisions and update risk profile both at
implementation stage and through life
•
Update maintenance planning and task
priorities
•
Provide effective failure mode management
in response to changing equipment condition
•
Record operating knowledge even if
staff/contractors change
•
Facilitate knowledge transfer across the
asset portfolio
Lloyd’s Register Energy