Asset Integrity Confidence Enhancement: A Case Study in Enhancing Facilities Integrity through the Management of Inherited Risk from the Manufacturing and Fabrication Phase of a Facility's Life Cycle

Asset integrity management is an essential part of the Mechanical Integrity element in the Process Safety Management framework. Programs such as risk-based inspection evaluate operational risks and establishes inspection plans to prevent unplanned facility failures. However, an effective Asset Integrity practice should also consider residual risks originating from the manufacturing and fabrication phase. Neglecting these risks can lead to unexpected failures during operations. A recent incident arising from improper heat treatment of stainless steel components in high-temperature refinery service highlighted the need for enhanced integrity measures. In response to this, a materials assessment was initiated, analyzing data from the equipment quality dossier. Gaps in manufacturing and fabrication processes were identified, and mitigated by a customized inspection program. This paper discusses crucial factors during manufacturing and fabrication that may cause degradation of material properties, resulting in premature failure. Additionally, it explores safety risks and other identified gaps from the study, along with the corresponding mitigation measures.
Product Number: 51324-21067-SG
Author: Tan Su Anne; Nurul Asni Bt Mohamed; M Aswadi B Ton Alias; M Iskandar B Bakeri
Publication Date: 2024
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