Adapting your inspection programme in these challenging times

We are all living through extremely challenging times. As the situation around Covid-19 impacts on us personally and our families, we are all learning how to work differently, and, more often than not, remotely from the colleagues and assets that have been a constant in our working lives.

For operators of high-hazard plant, ‘business as usual’ in terms of inspection management, may not be feasible in light of these unprecedented factors. Shutdown / Turnaround scopes involving scores of contract personnel converging on a plant to deliver inspection and maintenance activities – whilst applying social distancing – is seemingly an unrealistic option for now. Operators are now considering options to ensure that plant integrity continues to be maintained, whilst ensuring the welfare of all stakeholders.

Axiom are on hand to advise on appropriate means of meeting your regulatory requirements and protecting your people and assets, whilst optimising intervention. Examples of this include:

  • Asset Prioritisation Exercises. What is the real ‘Achilles Heel’ on your plant? In these trying times, where can you get the most ‘bang for your buck’ in an optimised inspection scope? At Axiom, we can work with you to undertake a holistic review of your plant and existing inspection scopes, to ensure that, with a shorter intervention period and potentially reduced manning, you are addressing only the most crucial integrity and business risks. Our multi-disciplinary team – including team members with notable experience on the ‘client side’ for an alternative take – have the knowledge of asset degradation and through-life management to offer a pragmatic, rationalised strategy.
  • Postponement. The work highlighted above will provide the confidence that interventions can be pushed out or eliminated, channelling limited resources towards the right areas. Nonetheless, for Pressure Systems, formal notification to the HSE will be required should there be a desire to deviate from an upcoming ‘due date’ during this uncertain period. This can be done once and once only. Axiom, as SAFed members with a link through this to the HSE’s position, are uniquely placed to advise our clients on requirements surrounding the preparation of a robust postponement safety case that will ensure full regulatory compliance. For more complex cases, this can be augmented by specialist engineering input from our Mechanical and Materials teams.
  • Non-invasive inspection. So, as can be seen, support is on hand to ensure that you are only assessing what needs to be assessed, but are you inspecting these items in the most efficient manner? Targeted non-invasive inspection (NII) is another means of both supporting a postponement safety case, and bringing still-scheduled ‘invasive’ Shutdown / Turnaround inspection work outside of a congested ‘standard’ inspection window. NII could encompass nothing more involved than a detailed external visual examination, but the latest specialist NDT techniques can provide previously unimaginable levels of insight which, combined, may eliminate the need to open up an asset. Axiom are already working with a number of clients in a similar manner to keep their inspection / integrity programme moving, and bring tasks outside of a bottleneck situation with potentially-compromised Shutdown / Turnaround manning levels.

So really, the message right now is that we are all being pushed to ‘think smarter’ in the current climate. We are here to work with you to explore alternative strategies that get what needs to be done ‘done’ at this time. However, some alternative thinking around how we plan and deliver inspection may form the basis of an optimised integrity management strategy for the longer-term. We’d be delighted to be a part of setting you on that path to maximising your assets and minimising risk – through minimising intervention!

Mechanical integrity insight – pragmatic solutions to optimise your spend

As the restrictions surrounding Covid-19 lead to challenges in progressing plant integrity management strategies, operators are naturally likely to search for means of minimising intervention whilst maintaining existing levels of integrity assurance. This introduces challenges when operating ageing assets – time-based, and operationally-induced, degradation will continue to come to the fore, irrespective of the issues we are collectively facing at present.

Repair and eventual replacement of degraded assets may be an established practice on any given site, however it should be remembered that Repair / Replacement constitute only two of the four ‘R’s assigned to potential outcomes from a fitness for purpose assessment. By engaging the right integrity management partner, and asking the right questions of both them and other stakeholders on your site, the following could be achieved:

  • Run. You may be surprised at the level of redundancy in the design of your aged equipment. Just how damage-tolerant is your asset? By employing advanced fitness for purpose tools such as Finite Element Analysis, you can simulate the true response of your component under complex loading, removing much of the inherent conservatism seen in a codal assessment. This may provide justification and confidence in leaving ‘as-is’ – at least until an opportune intervention window.
  • Re-rate. Quite often the most straightforward means of achieving fitness for purpose is to consider re-rating a piece of equipment based upon the actual required demands on an asset. This could mean reducing a liquid level in a storage tank, or undertaking an assessment of a pressure vessel using current (or revised) Safe Operating Limits rather than nameplate values. This approach would also seek to exploit redundancy in a component’s design, and with many assets designed for a far-more onerous duty than needed, a small change to the conditions seen may make a big difference.

At Axiom, our Mechanical team will be delighted to work with you and guide you through the options available to arrive at the most cost-effective means of demonstrating ongoing component integrity. Working with our team, you can be assured of a pragmatic solution to your most pressing integrity management concerns, allowing you to focus your maintenance budget, and personnel deployment, where they are truly needed at this time.

Axiom helps with emergency visor manufacture

Axiom, as part of the Teesside Engineering Network (TEN), recently supported a call out for industry to donate any spare PPE to our NHS.  Frustratingly, due to supply chain shortages, we weren’t able to donate ourselves.  

However, we did respond to a call out from Mark Elliott, who is Deputy Head of Engineering at Hartlepool College of Further Education. 

Mark is one of a whole army of home ‘3D printer’ owners across the UK, who is busy printing off the plastic head bands pieces that form part of the protective visors.  Where Mark was struggling, was for the clear plastic sheet to complete the visor.  We’ve been able to source these sheets and supply him with enough sheets to manufacture 300.  This is an impressive tally as the turn out rate is ~ 12 per day and Mark has made 60 so far.  These are to be used by North Tees and Hartlepool NHS Trust.

The Engineers amongst you will have noticed from the photo that Mark has been able to ‘nest’ three of the head band components to improve production rates.

It costs about 80p to 3D print each visor, so we’ve also agreed to make a donation of £200 to help cover the cost of these items.

Well done to Mark and the College – we wish you every success in reaching your target!