Asset Integrity Improvement at Oil Processing Facilities Through Data Driven Decision Making

Abstract Asset integrity management has been a persistent challenge in the oil and gas sector for decades. Despite significant research and development, and the availability of numerous digital solutions offering comprehensive coverage for mechanical integrity management in complex facilities, catastrophic failures due to inadequate asset integrity management still occur. While these solutions can automate complex integrity assessments and improve efficiency, they are often underutilized for gaining a holistic understanding of site conditions. Extracting meaningful insights from asset integrity data is crucial for effective asset management. One oil processing facility discovered that its high leakage rate and maintenance costs stemmed from a limited approach to asset integrity data analysis. Instead of viewing the data holistically, they were analyzing it piecemeal. Recognizing this deficiency, the facility shifted its approach, prioritizing data-driven insights to strengthen decision-making. They developed comprehensive dashboards to improve visibility into site conditions. Insights from interactive dashboards enabled better understanding and predictability for failures, enhanced risk sensitivity and a cultural change from a reactive to proactive mindset. Within just six months, this change resulted in a dramatic reduction of more than 55% in the quarterly leakage trend and USD 250,000 in cost savings. The approach mentioned in the paper helps to simplify complex information enabling quick decision making at oil and gas processing facilities, petrochemical and/or chemical processing industries.