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Reliability-Centered Maintenance and Mechanical Integrity Management for Aging Onshore Oil and Gas Production Facilities
Subject area: Science,Engineering and Technology · Area of research: RCM and Integrity of Aging Oil and Gas Assets
Abstract
Many onshore oil and gas production facilities now operate beyond their design life, yet their maintenance programmes still follow calendar intervals set when the equipment was new, ignoring rising corrosion and hidden-failure rates. This study develops an integrated reliability-centered maintenance and mechanical integrity framework for a representative 25-year-old onshore facility, evaluated over a 15-year life extension. Active failure modes are optimized with Weibull renewal and delay-time models under a risk cap for safety and environmental consequences. Static equipment is managed by risk-based inspection with corrosion-rate updating and inspection effectiveness. Protective devices receive age-dependent proof-test intervals. Inputs are representative published values, not field data. Against the legacy calendar programme, reliability-centered task selection cut rotating-equipment failures by 53 percent and cost by 26 percent. Static-equipment loss of containment events fell from 16.9 to 7.1 with static intervals and to 4.6 with age-adaptive inspection. Only the age-adaptive strategy kept every safety instrumented function within its SIL 2 limit, and it reduced failures on demand by 60 percent. The integrated strategy cost USD 23.5 million over 15 years, 23 percent less than legacy and 5 percent more than static reliability-centered maintenance. That premium averts about one additional loss of containment or failure on demand per USD 0.4 million. The advantage widens as corrosion accelerates. With five failure records, poorly estimated failure models raised expected cost by 22 percent.
Keywords
reliability-centered maintenance; mechanical integrity; ageing facilities; risk-based inspection; delay-time model; proof testing; onshore oil and gas
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How to cite this paper
@article{1724116,
author = {Paul Chibuike Obetta, Susan Ochi Makut, Festus-Michael Uwagboe, Henry Chukwuemeka Olisakwe},
title = {Reliability-Centered Maintenance and Mechanical Integrity Management for Aging Onshore Oil and Gas Production Facilities},
journal = {Iconic Research And Engineering Journals},
year = {2022},
volume = {6},
number = {5},
pages = {343-384},
issn = {2456-8880},
url = {https://www.irejournals.com/formatedpaper/1724116.pdf},
abstract = {Many onshore oil and gas production facilities now operate beyond their design life, yet their maintenance programmes still follow calendar intervals set when the equipment was new, ignoring rising corrosion and hidden-failure rates. This study develops an integrated reliability-centered maintenance and mechanical integrity framework for a representative 25-year-old onshore facility, evaluated over a 15-year life extension. Active failure modes are optimized with Weibull renewal and delay-time models under a risk cap for safety and environmental consequences. Static equipment is managed by risk-based inspection with corrosion-rate updating and inspection effectiveness. Protective devices receive age-dependent proof-test intervals. Inputs are representative published values, not field data. Against the legacy calendar programme, reliability-centered task selection cut rotating-equipment failures by 53 percent and cost by 26 percent. Static-equipment loss of containment events fell from 16.9 to 7.1 with static intervals and to 4.6 with age-adaptive inspection. Only the age-adaptive strategy kept every safety instrumented function within its SIL 2 limit, and it reduced failures on demand by 60 percent. The integrated strategy cost USD 23.5 million over 15 years, 23 percent less than legacy and 5 percent more than static reliability-centered maintenance. That premium averts about one additional loss of containment or failure on demand per USD 0.4 million. The advantage widens as corrosion accelerates. With five failure records, poorly estimated failure models raised expected cost by 22 percent.},
keywords = {reliability-centered maintenance; mechanical integrity; ageing facilities; risk-based inspection; delay-time model; proof testing; onshore oil and gas},
month = {November},
doi = {https://doi.org/10.64388/IREV6I5-1724116}
}