Asset Integrity Challenges in Oil & Gas Process Facilities

Managing asset integrity is a complex activity in surface production facilities of an oil industry. Process equipment in an oil production facility is exposed to various damage mechanisms that may be active due to the presence of contaminants in the process streams. Proper material selection, maintenance programs, inspection monitoring and repair are the standard components of the Asset Integrity Management Process. The conventional way of approaching the problems caused by damage mechanisms such as Hydrogen Induced Cracking (HIC) and Stress Corrosion Cracking (SCC) in Pressure vessels is by way of repairs or replacements. Black powder deposits are also causing increasing concerns due to fouling and severe corrosion. One pressure vessel and one heat exchanger have been replaced in few facilities of Kuwait Oil Company during the past one year due to Hydrogen Damage and fouling. One more vessel with minor embedded defects is under inspection monitoring and engineering evaluation. Alternate remedies have been applied to minimize propagation of defects. This paper presents field experience and application of various inspection methods in detecting embedded defects, hydrogen induced damages in the early stages, application of preventive measures to extend asset service life and asset integrity. Under this process, various advanced NDT inspection techniques were applied to detect and monitor critical internal defects on pressure vessels. Root cause analysis, fitness for service (FFS) and Risk Based Inspection (RBI) study have been conducted as a part of mitigating risks and applying remedies.