Field-Based Approaches to Asset Integrity Management in Offshore Oil and Gas Operations: A Case-Based Review

Abstract

Offshore oil and gas platforms are essentially known for the rigorous environment they are subjected to, including high salinity, dynamic loads, and complicated operation processes. Though there are existing norms concerning the issue of AIM in the forms of API 580/581 and DNV-RP-G101, the use of the risk-based strategy in field level practice remains a great challenge, especially in the new areas for the production of offshore oil. Existing literature mostly involves developments in the derivation of the theory or a concept of technology without much emphasis on the relationship between the factors. The current study describes the qualitative multi-case field study of AIM implementation at three offshore platforms, including two in the Gulf of Guinea and one on the UK Continental Shelf, at differing levels of AIM process maturity. The case studies were analyzed using techniques from the field of engineering, including Failure Modes & Effects Analysis-FMEA, Root Cause Analysis, and Risk-based inspection, in addition to theme analysis. The case studies were conducted based on inspection and maintenance data, as well as condition monitoring, in addition to field interviews with the offshore personnel. The results indicated the presence of critical hazard-causing factors of corrosion under insulation, erosion corrosion, and bearings on each of the platforms. Also, the human reliability factors affected the outcome of the research, which undermined the digital solutions because of the skill gaps and drift of human performance. Platforms combining digital twin solutions, priorities of inspections on the basis of FMEA, and training of human reliability showed remarkable outcomes of 21-26% reduction in unplanned downtime, 18-22% increase in accuracy of inspections, and 10-15% reduction in maintenance costs. The results indicated the strong moderation of the aforementioned outcomes in respect of organizational readiness and workforce stability. The paper describes a socio-technical framework for AIM that explains how integrity performance for the future must be supported by alignment at the technical systems, human reliability, and leadership within the organization levels.