Hybrid Multi-Attribute Framework for Optimizing Turnaround Inspection Scope in Oil and Gas Facilities

Abstract After putting a new asset into continuous operation for a sufficient amount of time, the initial turnaround (I-TA) is recognized as a mandatory requirement in the Oil and Gas (O&G) industries. Its purpose is to verify the design and operational integrity of new equipment, ensuring that it is not affected by corrosion, fouling, fabrication and construction defects, or any other potential damage mechanisms. The primary objective of the I-TA is to minimize risks related to operations, health, and safety. I-TA also addresses baseline inspection development, material/design verification, and quality carryovers. To make a profitable decision without compromising asset integrity and meeting the intention of the I-TA, this work provides a structured framework for determining a cost-effective inspection strategy that provides satisfactory confidence in the equipment’s safe and reliable operation. Developing this cost-effective TA scope is quite complex and incurs considerations of a broad spectrum of issues. Therefore, the framework presented in this paper introduces a novel hybrid methodology that combines the multi-Attribute decision-making (MADM) technique with Multi-Dimensional Risk Analysis (MDRA). The objective of this 5D MADM methodology is to support operating facilities in identifying the appropriate and adequate I-TA inspection scope strategies and prioritizing operation, maintenance & engineering efforts to help deliver production operational targets by limiting the TA on to the equipment that internal inspection is necessary and avoid unnecessary replacement of internal parts (e.g., catalysts, desiccant, etc.) due to exposing the equipment to internal inspection. Furthermore, identify the inspection that can be performed non-intrusive and online, which can shorten the TA duration, minimize the business interruption, and maximize the plant availability. The methodology was deployed to different process units in newly constructed refineries, such as CDU, VDU, NHT/CCR, DHT, isomerization, etc. It has been proven successful in supporting the organization in developing a cost-effective I-TA scope. These use cases resulted in approximately an average 50% reduction in the original TA inspection scope and a reduction of around 30% in the TA duration. This minimizes business interruption costs, reduces the risk of cost overrun and schedule delays, ensures personnel safety, and minimizes environmental impact, i.e., Green TA.