{"id":58610,"date":"2022-03-12T11:42:00","date_gmt":"2022-03-12T11:42:00","guid":{"rendered":"https:\/\/abl-group.com\/abl\/?p=58610"},"modified":"2024-03-12T12:01:19","modified_gmt":"2024-03-12T12:01:19","slug":"overcoming-common-challenges-associated-with-aging-plants","status":"publish","type":"post","link":"https:\/\/abl-group.com\/abl\/all-media\/blog\/overcoming-common-challenges-associated-with-aging-plants\/","title":{"rendered":"Overcoming\u00a0common challenges associated with aging\u00a0plants"},"content":{"rendered":"\n<p><strong>An aging\u00a0plant is one that has typically been operating over several\u00a0decades and\u00a0is likely to have gone\u00a0through\u00a0significant\u00a0changes, ranging from modifications to expansions and design changes. As the asset gets older, there are\u00a0several\u00a0challenges that will inevitably arise, such as over or under maintained equipment, difficulties purchasing spare parts or changes in operating conditions that can lead to\u00a0corrosion, erosion, mechanical\u00a0damage,\u00a0and\u00a0other late life degraded\u00a0failures.<\/strong><\/p>\n\n\n\n<p>In this blog post\u00a0we discuss the\u00a0top\u00a0common challenges associated with aging assets and provide\u00a0helpful\u00a0tips on how to overcome them.\u00a0<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-materials-and-spares-management\">Materials and spares management<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-the-challenge\">The challenge:<\/h3>\n\n\n\n<p>As equipment gets older, it becomes more and more&nbsp;challenging&nbsp;to locate and purchase spare parts. With technology continuously advancing, the balance of spares holding becomes difficult as certified vendors may stop producing certain equipment, making&nbsp;the obsolete and&nbsp;hard to find&nbsp;for&nbsp;aging assets.&nbsp;<\/p>\n\n\n\n<p>An approach that companies could take is to replace the equipment, but this is a very complex and expensive\u00a0tactic for tackling\u00a0spares issues\u00a0if late in the lifecycle of the asset. For example, a company may struggle to find spare parts for a 50-year-old pump and decide to replace the whole pump with a new, modern one. Despite the fact that the new pump may, on its own, cost $100,000, many aspects\u00a0must\u00a0be taken into account\u00a0when making the decision to replace parts, in this case, that could be\u00a0the\u00a0instrument\u00a0control systems, the\u00a0electrical distribution\u00a0and the design, meaning the overall project may end up costing millions of dollars. You have to make sure that the value case for the modification is absolutely clear and achievable\u00a0to stakeholders, the dichotomy is that this is difficult to do in late life when the replacement is most likely required as equipment is beyond safe and useful life estimates.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-solution\">Solution:<\/h3>\n\n\n\n<p>The issue with spares is very much linked to the management of obsolescence. As equipment becomes obsolete,&nbsp;there&nbsp;are 3&nbsp;main strategies to&nbsp;consider&nbsp;following:&nbsp;<\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li>Purchase&nbsp;multiple&nbsp;spares from the&nbsp;marketplace&nbsp;before they become obsolete or are scrapped&nbsp;and store them. With this option, it is important to note that spares do go out of certification after a length of time, so it is important to ensure they are preserved properly under the vendor instructions.&nbsp;&nbsp;&nbsp;<\/li>\n\n\n\n<li>Look for&nbsp;interchangeable&nbsp;equipment&nbsp;component&nbsp;that may be available.&nbsp;They must be a like for like change&nbsp;to work in the environment that is needed&nbsp;and go through the&nbsp;Management of Change (MoC)&nbsp;process.&nbsp;<\/li>\n\n\n\n<li>In some cases, reverse engineer components&nbsp;in precision workshops.<\/li>\n<\/ol>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-inaccurate-or-lack-of-optimised-maintenance-strategies\">Inaccurate or lack of optimised maintenance strategies\u00a0<br><\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-the-challenge-0\">The challenge:<\/h3>\n\n\n\n<p>Equipment is over or under maintained because assets don\u2019t get benchmarked or optimised to reflect the changes that have\u00a0occurred,\u00a0and the data recorded is unstructured or missing. For example, when\u00a0trying to sustain 100,000 barrels of oil production, you want everything to work efficiently, so you would drive your maintenance and write maintenance strategies to reflect that. As the asset declines and ages, you develop a different approach in terms of how to conduct maintenance, and many companies don\u2019t update their strategies to reflect that.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-solution-0\">Solution:<\/h3>\n\n\n\n<p>To overcome this challenge, it is important to\u00a0invest into the continuous\u00a0review the\u00a0data produced by the asset and periodically update the\u00a0maintenance strategy throughout the lifecycle of the asset.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-obsolescence\">Obsolescence<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-the-challenge-1\">The challenge:<\/h3>\n\n\n\n<p>Obsolescence occurs when equipment or software is no longer supported with spares or servicing capability from its vendor. If the mean time between failures is\u00a0decreasing, at the back end of the bathtub curve,\u00a0and the ability to find spare parts or to maintain the equipment is decreasing because of obsolescence, then you have to either change the equipment out or decommission it and change the design in terms of operations.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-solution-1\">Solution:<\/h3>\n\n\n\n<p>The development of \u201cheat maps\u201d is an effective method for managing this issue and one that ABL has developed specifically for helping clients identify equipment\u00a0moving towards obsolescence.\u00a0<\/p>\n\n\n\n<p>When a piece of equipment moves from green to amber on the heat maps, this highlights that an investment strategy is required. As the equipment then moves from amber to red, the strategy should, by this point, be approved and ready to implement.\u00a0The process of equipment or software moving from amber to red indicates which strategies need to be reviewed and what solutions have to be implemented,\u00a0e.g.,\u00a0will the equipment be stripped out or will the spares holding change?\u00a0<\/p>\n\n\n\n<p>Below is an example of this type of heat map.<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/3825857.fs1.hubspotusercontent-na1.net\/hub\/3825857\/hubfs\/MicrosoftTeams-image.png?width=641&amp;name=MicrosoftTeams-image.png\" alt=\"MicrosoftTeams-image\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-inspection-anomaly-management\">Inspection anomaly management<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-the-challenge-2\">The challenge:<\/h3>\n\n\n\n<p>When an inspection is conducted and problems that may affect integrity such as erosion or pipe wall failures are found, these are referred to as anomalies. Assets that were designed to last 25 years have now been in use for 40 years or more, meaning the pipes get thinner and sometimes fail. The older the platform is, the more anomalies occur, so it is important to find a way to manage the volume of anomalies.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-solution-2\">Solution:<\/h3>\n\n\n\n<p>To\u00a0manage\u00a0anomalies effectively, it is critical to\u00a0ensure the areas of highest risk are prioritised and that the applied strategies are producing positive results. Revisit where the\u00a0initial\u00a0baseline\u00a0survey\u00a0is and make sure you are limiting the amount of pipe containment failures at all times.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-small-bore-piping-vibration\">Small bore piping vibration<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-the-challenge-3\">The challenge:<\/h3>\n\n\n\n<p>As assets age, the profile of fluids that go through them change and the way different parts of the plant operate can also change. For example, with a relatively new platform you\u00a0could extract\u00a0up to 100,000 barrels of oil, but after 30 years you may only get around 10,000 of oil, but 250,000 barrels of water. Some pumps and compressors may be working at much lower loads (with higher recycle rates) and some may be working much harder than they ever needed to. With the density changes between oil and water, and the changes in use and operating profile of the machinery, vibration problems can arise in parts of the plant that were previously low risk.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-solution-3\">Solution:<\/h3>\n\n\n\n<p>To mitigate this, a clear strategy for managing the vibration risks\u00a0must be in place. This strategy will allow the changing risk profile to be captured and will allow potential high risk small bore and mainline problems to be identified before failure occurs. This can be done by taking the time to engage with the right people to conduct small bore pipe work surveys when required and at intervals that are appropriate to the overall asset integrity management plan.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-technicians-competency\">Technicians competency<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-the-challenge-4\">The challenge:<\/h3>\n\n\n\n<p>In many cases,\u00a0operations and maintenance\u00a0technicians on site have been there since the asset was produced,\u00a0which comes with its own set of challenges. As these people retire, they take with them their knowledge of the asset which can sometimes leave gaps in the\u00a0understanding of the\u00a0operations and\u00a0history of the asset.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-solution-4\">Solution:<\/h3>\n\n\n\n<p>The best solution for this is to make sure there is really efficient knowledge transfers for new technicians that are being recruited into the industry, and that they are learning from experienced\u00a0technicians.\u00a0Capturing this knowledge in high quality written procedures and videos\u00a0before this happens is highly effective for getting the next generation of technicians up to speed.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-poor-management-of-change\">Poor management of change<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-the-challenge-5\">The challenge:<\/h3>\n\n\n\n<p>A significant challenge with aging assets is that there has been poor management of change. This includes engineering projects, minor modifications, procedures, processes, standing instructions, asset registers and drawings. The management of change could be equipment upgrades, modifications to systems and decommissioned\u00a0or mothballed\u00a0equipment, all contributing to the asset register being out of date.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-solution-5\">Solution:<\/h3>\n\n\n\n<p>To overcome this challenge, it is essential to ensure there is discipline as well as a really clear and simple methodology for managing change. <a href=\"https:\/\/abl-group.com\/abl\/effio\/\">Effio <\/a>is a strong system to use to manage change within\u00a0the CMMS system, for both integrity and maintenance management.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-how-abl-can-help-with-aging-plants\">How ABL can help with aging plants<\/h2>\n\n\n\n<p>ABL&#8217;s asset management experts specialise in designing,\u00a0implementing,\u00a0and optimising our\u00a0client\u2019s\u00a0<a href=\"https:\/\/abl-group.com\/abl\/consulting-and-engineering\/asset-and-integrity-management\/operational-excellence\/53437-2\/\">asset management strategies<\/a>\u00a0across the entire life cycle of their plants.\u00a0\u00a0<\/p>\n\n\n\n<p>The CMMS, ERP or EAM&nbsp;system&nbsp;provides&nbsp;an effective&nbsp;mechanism for&nbsp;managing maintenance, integrity and materials&nbsp;for the plant and it is key that the strategies and implementation tactics&nbsp;within the system align with the&nbsp;requirements of the&nbsp;operational phase&nbsp;that the plant is in.&nbsp;&nbsp;&nbsp;<\/p>\n\n\n\n<p>From initial design through to decommissioning\u00a0and disposal, ABL\u00a0helps plant operators spend money in the right place to mitigate risk and assure profitability.\u00a0\u00a0<\/p>\n\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link has-blue-background-color has-background wp-element-button\" href=\"https:\/\/abl-group.com\/abl\/consulting-and-engineering\/asset-and-integrity-management\/\">learn more about abl&#8217;s asset &amp; integrity management services<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:52px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n","protected":false},"excerpt":{"rendered":"<p>An aging\u00a0plant is one that has typically been operating over several\u00a0decades and\u00a0is likely to have gone\u00a0through\u00a0significant\u00a0changes, ranging from modifications to expansions and design changes. As the asset gets older, there are\u00a0several\u00a0challenges that will inevitably arise, such as over or under maintained equipment, difficulties purchasing spare parts or changes in operating conditions that can lead to\u00a0corrosion, [&hellip;]<\/p>\n","protected":false},"author":20,"featured_media":58613,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[6],"tags":[],"sector":[959],"service":[955],"company":[724],"class_list":["post-58610","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog","sector-asset-integrity-management","service-asset-and-integrity-management","company-abl"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v23.6 (Yoast SEO v27.3) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Overcoming\u00a0common challenges associated with aging\u00a0plants - ABL<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/abl-group.com\/abl\/all-media\/blog\/overcoming-common-challenges-associated-with-aging-plants\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Overcoming\u00a0common challenges associated with aging\u00a0plants\" \/>\n<meta property=\"og:description\" content=\"An aging\u00a0plant is one that has typically been operating over several\u00a0decades and\u00a0is likely to have gone\u00a0through\u00a0significant\u00a0changes, ranging from modifications to expansions and design changes. As the asset gets older, there are\u00a0several\u00a0challenges that will inevitably arise, such as over or under maintained equipment, difficulties purchasing spare parts or changes in operating conditions that can lead to\u00a0corrosion, [&hellip;]\" \/>\n<meta property=\"og:url\" content=\"https:\/\/abl-group.com\/abl\/all-media\/blog\/overcoming-common-challenges-associated-with-aging-plants\/\" \/>\n<meta property=\"og:site_name\" content=\"ABL\" \/>\n<meta property=\"article:published_time\" content=\"2022-03-12T11:42:00+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2024-03-12T12:01:19+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/03\/MicrosoftTeams-image.webp\" \/>\n\t<meta property=\"og:image:width\" content=\"641\" \/>\n\t<meta property=\"og:image:height\" content=\"360\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/webp\" \/>\n<meta name=\"author\" content=\"Airlie McIntyre\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Airlie McIntyre\" \/>\n\t<meta name=\"twitter:label2\" content=\"Estimated reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"7 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/all-media\\\/blog\\\/overcoming-common-challenges-associated-with-aging-plants\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/all-media\\\/blog\\\/overcoming-common-challenges-associated-with-aging-plants\\\/\"},\"author\":{\"name\":\"Airlie McIntyre\",\"@id\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/#\\\/schema\\\/person\\\/ab2c193d93122c2b067e5efbcc4f0c68\"},\"headline\":\"Overcoming\u00a0common challenges associated with aging\u00a0plants\",\"datePublished\":\"2022-03-12T11:42:00+00:00\",\"dateModified\":\"2024-03-12T12:01:19+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/all-media\\\/blog\\\/overcoming-common-challenges-associated-with-aging-plants\\\/\"},\"wordCount\":1458,\"publisher\":{\"@id\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/#organization\"},\"image\":{\"@id\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/all-media\\\/blog\\\/overcoming-common-challenges-associated-with-aging-plants\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/wp-content\\\/uploads\\\/2024\\\/03\\\/MicrosoftTeams-image.webp\",\"articleSection\":[\"Blog\"],\"inLanguage\":\"en-GB\"},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/all-media\\\/blog\\\/overcoming-common-challenges-associated-with-aging-plants\\\/\",\"url\":\"https:\\\/\\\/abl-group.com\\\/abl\\\/all-media\\\/blog\\\/overcoming-common-challenges-associated-with-aging-plants\\\/\",\"name\":\"Overcoming\u00a0common challenges associated with aging\u00a0plants - 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