iicorr Ltd


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The following case study is based on a real life asset, located within the UK Continental Shelf (UKCS). In this particular instance, iicorr enabled inspection regime cost savings of 47%.

Job Scope:	Date: 12 August 2003

Using iicorr's Questar-P methodology (which incorporates latest industry best practices), iicorr were called upon to develop a risk-based inspection programme for process plant incorporating 18 vessels and associated pipework.

Inspection Activity Expenditure, prior to Application of QUESTAR-P:
Based on a five-year inspection strategy previously in place for the asset, and by attributing standard costs to each inspection activity, it was possible to estimate the operator's total inspection expenditure during the five years from 1999 to 2003 prior to the application of Questar P. The cumulative value of this expenditure was found to be approximately £960,000 (GBP), over the five year period in question.

The Questar P Methodology:
Our own Questar-P inspection methodology was used to fully optimise the operator's five-year inspection programme. This required a phased approach, initially defining the process services involved before developing likelihood and consequences of failure and subsequent risk and criticality. These results determine the level of assessment each item receives using deterioration models to calculate optimal inspection intervals.

Factors considered included:
Item design and physical properties;
fluid operating properties and recent/future changes; predicted corrosion rate and remaining life calculations applicable to failure mode; results and frequency of any previous inspections; NDT data; corrosion monitoring data; and, qualitative item level review of probability and consequence.

Throughout the assessment process, members of iicorr's dedicated engineering team performed validity checks at key project stages; this, in addition to the application of extensive engineering expertise were applied to ensure the highest possible levels of service quality and integrity.

Associated inspection activity costs following our application of Questar-P :
Following application of the Questar-P methodology, inspection, monitoring and mitigation methods were recommended in order to provide future assurance of facility integrity. This, in effect, extended inspection intervals and reduced the number of costly internal vessel interventions by focusing inspection resource more efficiently. On a like-for-like basis, forecast inspection expenditure over the five year period 2004 to 2008 was forecast to be approximately £510,000 (GBP); this being a 47% expenditure reduction. In addition to these predicted savings in expenditure, a fully auditable inspection rationale was provided to underpin the inspection regime set in place.

Overall :
The application of iicorr's Questar methodologies, not only provide our customers with tangible cost savings (as demonstrated in the example above); they also enhance the critical intangible value associated with the assurance of facility integrity, minimal production loss, personnel safety and environmental preservation.