Asset Integrity Management refers to the management system that enables plant owners to maintain the integrity of their assets in a Fit-for-Service (FFS) condition for the desired lives of the assets.
A sound Asset Integrity Management Services (AIMS) program incorporates various aspects of equipment design, maintenance, inspection programs, and operational management in order to ensure safety and efficiency and to maximize an asset’s financial return. In short, MISTRAS helps our clients realize longer run time, reduced downtime, and enhanced mechanical integrity.
MISTRAS' expert engineering consultants can help to audit and optimize existing AIMS/MI programs, or help plants develop them from the ground-up using proceduralized methodologies.
Customized AIMS/MI Programs
MISTRAS customizes AIMS programs to fit each individual customer’s facilities, drawing from a blend of:
- mechanical integrity (MI) and risk based inspection (RBI) program development
- gap analyses of existing programs to assess where existing mechanical integrity programs may be ineffective.
- mechanical integrity software
- traditional and advanced non-destructive testing (NDT) techniques
- online monitoring systems & services
- development of site-specific manuals for all employees to adhere to the AIMS program
MISTRAS also provides Engineering Fitness-for-Service (FFS), Finite Element Analysis, and other fixed equipment mechanical engineering studies to enhance run-repair-replace decisions.
Mechanical Integrity Audits
A sound Mechanical Integrity program can prevent catastrophic equipment failure, less-than-reliable operation, and high maintenance costs, all while ensuring the safety of employees, people, property, and the environment — all of which are serious concerns.
MISTRAS' AIMS/MI programs offer an independent assessment of an owner and user’s program condition utilizing a state-of-the-art GAP analysis methodology. Deficiencies inhibiting a company’s asset integrity program are identified and corrective measures are recommended. Our Mechanical Integrity experts can advise clients who are developing a new MI program, or those looking to optimize an existing program.
Our Mechanical Integrity program gap analysis services offer insight into the level of plant readiness, how best to manage and monitor the integrity of process facility assets, and how to extend the useful lives of such assets. Our MI consulting experts also assists customers in benchmarking and managing their infrastructure through key performance indicators (KPIs) and other metrics.
ISOTRAC™: A Proactive Approach to AIMS/MI
MISTRAS’ ISOTRAC™ solution is a proactive approach for pre-developing an AIMS program, specifically developed for implementation within new plants in the downstream, midstream, upstream, chemical process industries.
ISOTRAC is integral in the development of an Asset Integrity Program compliant with industry regulatory requirements at the time of commissioning. Facilities that implement an ISOTRAC system during the design and construction phase of a new facility can start up by meeting or exceeding compliance with current MI regulations.
ISOTRAC is a specific multi-phased methodology to develop AIMS programs by illustrating each element within a facility, using a specific system of organization to determine best-fit solutions and remedies through:
- Systemization
- Damage and Corrosion Analysis
- Circuitization
- Extraction of Inspection Isometrics and design data from the 3D Model
- Develop Inspection and Test Plan
- Assignment of Condition Monitoring Locations (CMLs)
- Generation of inspection & test plans effective for the anticipated damage mechanisms
- Data is Recorded Into the PCMS or other IDMS systems
The ISOTRAC™ system begins with Systemization of a facility’s piping and equipment, followed by a comprehensive damage and corrosion analysis to evaluate all potential damages affecting each system. Each system is broken down into additional circuits, containing the same corrosion and damage potential.
Next, the 3D design model is used to provide necessary data for extracting inspection isometrics and circuit groupings, which are analyzed for Condition Monitoring Location (CML) assignments. Each CML is assigned based on anticipated damage and corrosion mechanisms and inspection and tests plans, and are developed based on the damage and corrosion analysis assigned to each CML.
The final phase of the ISOTRAC system transfers piping and equipment designs, Process Safety Information (PSI), CML inspection data and inspection, and test plans into a usable form for the facility’s records.
AIMS Program Data Management
An effective AIMS program is data-driven. Plant maintenance personnel need to stay informed of historical asset inspection data, corrosion rates, next inspection dates, retirement limits, and engineering calculations. Data is prepared for facility personnel and recorded into MISTRAS’ Plant Condition Management System (PCMS) or other Inspection Data Management Software (IDMS). PCMS is an industry-leading inspection database management software (IDMS) that stores, organizes, and analyzes all of a plant’s mechanical integrity data, and links that information across any technology platform.
The ISOTRAC™ system utilizes PCMS and other top-tier IDMS software to facilitate a comprehensive list of software modules including:
- Pressurized Threshold Monitoring
- Temperature
- Corrosion Control Documentation
- Risk Management
Facility Integrity Management Programs
MISTRAS' Facility Integrity Management Program determines the likelihood of both internal and external damage using risk-based analysis on a facility or piping group.
An AIMS engineer will review all client-provided data including facility drawings, inspection and repair reports, corrosion records, and other pertinent documents to gather accurate data for the individual pipeline segments. A field visit is often used to collect additional operating data and verify existing data from the records review. This information is reviewed and applied to several risk-based factors weighted according to client preferences.
The pipeline condition algorithm calculates the risk-ranking of each pipeline segment in the facility or pipeline group and assists in identifying those pipeline segments that warrant additional review or NDT inspection.
MISTRAS offers a variety of NDT inspection methods including traditional UT, guided wave UT (GUL), C-scan, and most other available technologies. A report is issued documenting the integrity methods used, the line segments of interest and the recommended actions, and NDT inspections that are required to verify the integrity of the pipeline group.
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