Asset Integrity Management Readiness: How to set new facilities up for success

In today’s competitive environment, when developing a new facility or greenfield project, it is crucial to define all Asset Integrity Management (AIM) strategies in advance, starting at the design and construction phases. This proactive approach ensures that you can operate and maintain your facilities properly and efficiently from the start-up day, guaranteeing operational efficiency and effective risk management throughout the asset’s lifecycle.

ABL’s US Country Manager for Asset Integrity Management, Luis Gonzales, has reflected on his extensive experience in the energy sector and delved into key strategies and methodologies essential for preparing new facilities to achieve long-term success, operational efficiency, and sustainable performance.

The challenge with managing assets in Greenfield projects

Implementing an Asset Management Readiness program during the design and construction phases of new facilities or greenfield projects is crucial to overcoming challenges in the operations and maintenance phase. Key areas include:

Asset management tasks and work management

Without predefined strategies, new facilities risk unplanned downtime, reduced asset lifespan, and safety hazards. Developing preventive and predictive maintenance plans early, while including integrity management, process safety, and compliance measures, ensures maintenance activities are seamlessly aligned with operations, safeguarding both performance and safety.

Risk management

Identifying and addressing potential hazards in untested facilities is vital. Using FMECA (Failure Modes, Effects, and Criticality Analysis) early allows systematic evaluation of failure modes, prioritisation of mitigation efforts, and the creation of a detailed risk register to enhance preparedness.

Data management and integration

A Master Data Management (MDM) framework ensures critical asset information—such as equipment specifications and maintenance history—is accurate and accessible. Selecting the right Asset Information Management software early aligns data with operational needs. Stakeholder involvement in configuring and testing ensures successful implementation.

Resource allocation

Effective allocation of personnel, materials, and finances is essential for operational efficiency. Careful planning ensures resources align with asset management goals.

Regulatory compliance

Adhering to evolving regulations is mandatory to ensure safety and avoid legal penalties. Processes for monitoring compliance are essential.

By addressing these challenges through an Asset Management Readiness program, incorporating MDM frameworks and tailored AIM software—organisations can ensure long-term operational success and sustainability in Greenfield projects.

How to set new facilities up for success

Setting up a new facility is a significant undertaking that requires detailed planning, especially when it comes to Asset Integrity Management. Here is how you can provide a solid foundation for long-term success in your new facility:

Asset registers and equipment criticality

Challenge: New facilities often start with little to no formalised asset register, which is crucial for tracking and managing equipment over time. Without a structured asset register, essential equipment may be overlooked and unprioritised, leading to inefficiencies and increased risk.

Benefits: Establishing a comprehensive asset register and defining equipment criticality helps make sure each piece of equipment is accounted for, prioritised, and documented based on its importance to operations and the business.

A thorough asset register provides visibility and enables targeted maintenance efforts, improving reliability, integrity, and reducing the likelihood of unexpected failures. By focusing resources on critical equipment, organisations can ensure smoother and more efficient operations from the outset.

Reliability-centred risk management

Challenge: Implementing an effective risk management strategy in new facilities is challenging due to the difficulty in identifying potential failure modes and their consequences. Without a structured approach, organisations may overlook critical hazards, leading to costly breakdowns, increased downtime, and safety incidents.

Benefits: Employing methodologies like Failure Modes, Effects, and Criticality Analysis (FMECA) during the design and construction phases enables a thorough assessment of potential failure modes. This process helps evaluate the likelihood and impact of each failure, facilitating the development of targeted mitigation actions or tasks to be integrated into AIM strategies.

A reliability-centred approach to risk management allows organisations to proactively identify and address issues before they escalate, thereby protecting assets, personnel, and the environment. This strategy reduces downtime, enhances safety, and establishes a robust operational foundation for the facility’s lifecycle.

Comprehensive asset management strategies

Challenge: New facilities require integrated asset management plans encompassing operations, maintenance, integrity management, and process safety to achieve production targets safely and consistently. Without a well-defined strategy, unplanned outages, inefficiencies, and safety incidents can occur due to inadequate preparation.

Benefits: Developing customised asset management strategies involves:

• Operations: Establishing standard operating procedures (SOPs) and training programs to ensure efficient and safe facility operations.
• Maintenance: Creating preventive and predictive maintenance plans, supported by a comprehensive Bill of Materials (BoM) that includes necessary spare parts.
• Integrity Management: Implementing systems to monitor and maintain the structural and functional integrity of assets throughout their lifecycle.
• Process Safety: Identifying potential hazards and implementing controls to prevent incidents, ensuring compliance with safety regulations.

An optimised asset management strategy enhances operational reliability, extends equipment lifespan, and improves safety performance. By having critical spare parts readily available and well-trained personnel, facilities can respond promptly to maintenance needs and ensure smooth operations. Additionally, robust integrity management and process safety measures protect assets, personnel, and the environment, contributing to sustainable and efficient facility performance.

Operations & Maintenance (O&M) Training

Challenge: In new facilities, operational staff are often unfamiliar with the specific systems and processes in place. Without structured training, staff may be unprepared to manage equipment, leading to inefficiencies and increased risk.

Benefits: Providing in-depth O&M training materials tailored to the facility’s unique requirements equips staff with the knowledge and skills needed to manage assets effectively and safely.

Competent staff are more capable of operating and maintaining equipment, reducing the likelihood of user errors, improving efficiency, and most importantly supporting a culture of safety. This foundation of knowledge contributes to smoother, more effective facility operations.

Asset Information Management system selection and implementation

Challenge: Selecting and implementing a comprehensive Asset Information Management system—such as a Computerised Maintenance Management System (CMMS), Enterprise Asset Management (EAM), Asset Performance Management (APM), Asset Investment Planning (AIP), or Integrity Management System (IMS)—is critical for efficient operations.

New facilities often face the challenge of choosing the right system without prior operational insights, which can lead to integration issues.

Benefits: A structured approach to system selection and implementation ensures that the chosen solution aligns with the facility’s goals, supports future growth, and integrates well with other operational systems. Involving key stakeholders, such as the document control team, in the system’s configuration design, testing, and rollout is essential for successful implementation.

A carefully selected and implemented Asset Information Management system simplifies data management, maintenance scheduling, benchmarking, analysis, and performance monitoring. The right system enables data-driven decision-making, automates processes, and provides a foundation for scaling operations efficiently as the facility grows.

The outcome: full visibility and optimised Operations and Maintenance processes

By implementing the strategies above, you can obtain complete visibility over your equipment and operations, allowing you to operate and maintain assets at optimal levels, assuring performance and monitoring and managing risk.

From minimising downtime to effectively managing risks, having a well-defined asset management strategy is essential for achieving operational excellence.

By investing in each of these AIM readiness services, new facilities are well-prepared to handle operational demands from day one, setting you up for long-term success, sustainability, and resilience in any new-build facility.

Effio™: our tool for simplified asset management

Our proprietary software, Effio™ is designed to be a one-stop solution for controlled, efficient, consistent, and connected deployment of your asset management strategy across a range of projects—whether for new facilities, operational upgrades, mergers & acquisitions, or plant modifications.

Ready to strengthen your Asset Integrity Management strategy?

Discover how our AIM services can set your new facility up for success. By investing in a structured approach, you can ensure long-term productivity, safety, and sustainability.

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