Abqaiq Plants Asset Management Journey
As the largest energy provider to the world in the oil and gas field, asset management is not considered as a
luxury, yet it is considered as a necessity specially for an aging facility (83 years) in order to remain a reliable
supplier to the world. In fact, Asset Management is considered as one of the major pillars in Abqaiq Plants
that spread the reliability culture and ensure being resilience as one of the most important characteristics.
The following report will show several programs that directly uplift the plant reliability and proof sustainability
is one of the imbedded cultures across Abqaiq Plants.
These strategies support Abqaiq Plants to Plan, design, procure, and construct reliable and efficient assets in
accordance with HSE requirements, Company standards, best practices, and government regulations to ensure
that all assets required for achieving performance objectives are identified and assessed with respectto critical
performance and condition parameters, degradation mechanisms, and failure risks and impacts.
Abqaiq Plans regularly manage the maintenance of assets through TPRM system (Total Plant Reliability
Management) and trough Asset Integrity Management System. (AIMS)
Abqaiq Plants New
Maintenance Programs &
Technologies
- Abqaiq Plants Reliability Center for Online Asset Monitoring and
Prediction System on Critical Rotating Equipment
Abqaiq Plants took a step toward IR 4.0 implementation by introducing Reliability Center concept for rotating
equipment. The Reliability & Asset Condition Monitoring concepts have been evolving for a long time with
increasing complexity and capabilities. This was further complicated by the introduction of IR 4.0concept.
Therefore, Abqaiq Plants have taken a proactive step and introduced a concept of integrated condition
monitoring along with the new implementation of new state-of-art condition-monitoring techniques utilizing
Ultrasound monitoring and Thermography inspection for rotating equipment. The new development of Abqaiq
Plants modern integrated condition monitoring concept means combining and interpretation of all monitoring
data available to monitor changes over time. This integrated approach has automated loop of learning that
can detect emerging threat and will stop further degradations and make synergic enhancements that
continuously improves asset reliability. Along the pathway, Abqaiq Plants has taken further step to be ready
for IR 4.0 implementation that requires access to accurate and different sources of data to trust it for decision
making by introducing Abqaiq Plants modern integrated condition monitoring program.
A number of significant enhancements were done to the program to include but not limited to, Utilizing the
PeakVue™ Technology analysis, Establishing the Ultrasound healthy baseline for equipment, Creating the
Thermography inspection for rotating equipment, and capitalizing on Online asset monitoring and health
analysis solutions. The new Asset Condition Monitoring Program went live in 2022, thus, highlighting the
monetary benefits gained from these enhancements. - Abqaiq Plants Critical Asset Prediction System (CAPS) on Critical
Rotating Equipment
Abqaiq Plants Critical Asset Prediction System, CAPS is a
new early diagnostic system that monitors any abnormal
change of rate in rotating equipment operating
parameters. The system integrated various live data from
PI System such as vibration, temperature, pressure, and
flow measurement, etc. to provide the change of rate
percentage over a defined period of time. The system uses
automatic and autonomous asset faults classification by
integrating different online monitoring methods through centralized reporting approach. This prevents
premature equipment failures and reduce Breakdowns/Trips. Each equipment monitoring parameters for
example vibration and temperature are customized depending on the criticality of rotating equipment. CAPS
is a predictive tool that rely on set of measurements and data acquisition to detect degradation and monitor
assets performance to avoid any significant deterioration in the component physical condition.
3. Integrated Camera Gas Detection ICGD system
This technology works by integrating the surveillance camera systems with field gas sensors in the plants. Gas
sensors in different locations across the plant will be connected to the cameras in the area through a
serial/network interface. In case of any gas leak, the site sensors will automatically send a signal to the
camera covering that area to rotate and display the leak location.
On the safety aspect of this link, the safety feature will provide prompt and instant detection of any leak in
the area for the DCS personnel for rapid intervention. Also, the uniqueness of this system comes from the
automation, and no man intervention Is required. This technology was deployed in the plant and proven to be
a very effective and reliable solution to detect any harmful gases release to the atmosphere.
Also, this technology will help the team to minimize the losses and provide a cost-effective solution to mitigate
large scale failures which lead to more spending to be restored. Also, for the deployment of this connection
will not require any addition costs to implement this function. (system configuration and build-infunctions).
Restoration of steam turbine via reverse engineering
technologies
Abqaiq plants efforts in collaboration with Aramco’s central engineering to pilot reverse engineering
methodology to return an obsolete single-stage steam turbine back to service with less expensive, more
efficient, & higher quality and durability spare parts. In addition, the article illustrates the achievement of
completing the 1st blades fabrication in middle east with a total cost of only 15% of new blades and rotor that
were offered during the spare parts material sourcing activities.
The reverse engineering technology capitalizing on local resources and capabilities in collaboration with Saudi
Aramco Central Engineering and the mechanical services shop. This action was taken to overcome critical
equipment outage and minimize repair cost and time.
Abqaiq plants worked jointly in collaboration with Saudi Aramco Central Engineering and the mechanical
services shop, agreed with approved and trusted vendors to do a complete fabrication of the broken blades,
which involved critical dimensions and accurate fabrication capabilities. - Non-metallic integration in multistage pumps
Abqaiq Plants has Boiler Feed Water Pumps (BFWP) that are multistage pumps. Multistage pumps are relatively
high energy pumps that their efficiency plays a major role in power consumption. BFWP handles condensate
water at high temperature which, in conventional metallic pumps, requires high clearances to allow metal
expansion. In fact, high clearances allow liquid internal circulation in the pump which obviosity undesirable
phenomena because it drops pump efficiency. Although Abqaiq Plants’ BFWP have been in operation since
1970s, Abqaiq Plants is continually looking for opportunities to improve equipment reliability and efficiency
which in line the Abqaiq Plants mission to apply state-of-art technologies.
Abqaiq team set a plan to upgrade the existing BFWP to non-metallic internal parts after the success of two
pumps upgrade. The criteria of successful upgrade were including performance and efficiency. The pump
efficiency improved by 4% and resulted in drop of energy consumption, in the form of brake horsepower,
dropped by 6%. Also, the pump reliability was increase due to non-metallic capability to mitigate instant
process upsets. This upgrade is considered the first in the region if not globally. - Lube oil Handling program
Abqaiq plant has a fleet of rotating equipment (pumps, compressors, turbines, motors) installed within the
facility. As part of the machine condition monitoring programs, the Lube Oil monitoring and handling play a
significant role in maintaining machine integrity and health. Insufficient lubrication and contamination
account for more than 20% of the machine and internal component failures. For that, Abqaiq plant successfully
established and deployed a lube oil handling program that assures a straightforward way of handling lube oil
in different rotating equipment at the facility.
The program objectives:
1. Preventing any lube oil cross-contamination and undesirable mixing.
2. Preventing Ingress of environmental dirt and water by using unsealed tanks or containers.
3. Preventing the failures related to the oil contamination such as the bearing failures.
4 .Improving the user experience with lube oil handling and storage.
The program managed to provide the ensure that the proper lubrication of the rotating equipment is
maintained. Thus, the outcomes of this program are as follows:
1. reducing the failures caused by the improper contamination and insufficient lubrication
2. increase the machine availability.
3. Reduction in non-compliance sample. - Thermography Technology Deployment in Detecting Mechanical Seal
Failures
Thermography is a predictive maintenance technique that can be used to monitor the condition of plant
machinery, structures and systems. This technology works be detecting the heat emitted by the objects and
equipment and help the users to understand the nature of the system they are going to deal with. Some
common applications that thermography can be a major player in areas like electrical applications, Steam
components inspection, Mechanical Stresses and Equipment misalignments, and to observe the liquid levels
inside storage units and crude tank.
When it comes to the rotating equipment, the sealing systems accounts for more than 55% of the machine
root cause of failure, and if you breakdown this percentages, we noticed that the leading factor for the
majority of those failure are operational deficiencies and one of the main types for this failure is the lack of
lubrication i.e. seal flush plans.
To mitigate and improve the rotating machinery health, ABQ team has developed a PM program to targetthe
high number of mechanical seals failures due to the of seal faces lubrication. The program also established to
overcome the absence of detection tools and technologies in the market and the frequent seals piping and
orifices blockages.
During the year 2021, the team managed to publish 13 Pdm alerts have been issued among the 217 equipment
currently enrolled in the program. The total cost avoidance generated is equipment to $500,000 which is the
cost of the mechanical seals replacement. Also, other revenues were acquired by maintaining high MTBF
figures.
02 Award & Recognitions
Abqaiq Plants Maintenance Department Awards and Recognitions
Abqaiq Plants was recognized for its excellence journey in consistently enhancing maintenance and reliability
performance. Abqaiq Plants received below well-recognized awards and recognitions which reflects Abqaiq
Plants employees’ caliber and commitment to the plant’s safety and reliability.
Awards Description
1.
2021 President’s Maintenance &
Reliability Excellence Award
The President’s Maintenance & Reliability Excellence Award
Golden title was awarded to Abqaiq Plants Maintenance
Department for the year 2021. APMD demonstrated great
strides in all evaluated criteria, and exceptional stance in the
culture criteria. This award is a testimonial to Abqaiq plants
employees’ caliber and commitment to the plant’s reliability &
maintainability.
2.
2020 President’s Maintenance &
Reliability Excellence Award
The President’s Maintenance & Reliability Excellence Award
silver title was awarded to Abqaiq Plants Maintenance
Department for the year 2020. APMD demonstrated great
strides in all evaluated criteria, and exceptional stance in the
culture criteria. This award is a testimonial to Abqaiq plants
employees’ caliber and commitment to the plant’s reliability &
maintainability.
3.
Abqaiq Plants recognition by the
World Economic Forum “WEF” as
an IR 4.0 Lighthouse Facility for
the Y-2021
Abqaiq Plants has been recognized as an IR 4.0
lighthouse facility by the World Economic Forum
(WEF) for its innovative and extensive deployment
and use of IR 4.0 tools and technologies.
4.
The 2021 ME RoTIC Reliability
Excellence award
The Middle East Rotating Machinery Technology & Innovation
Conference and showcase (ME RoTIC) awarded Abqaiq plants
the Reliability Excellence award for the year 2021. This award
recognizes Abqaiq Plants for its excellence journey in
enhancing the Condition Monitoring Program. The award is a
testimonial to Abqaiq Plants employees’ caliber and
commitment to the plant’s safety and reliability.
5.
Saudi Aramco Maintenance
Workforce Recognition Program
Abqaiq Plants Reliability Engineer Gonzalez Quinones, Andres E was
recognized to be among the top five achievers in Maintenance Workforce
Recognition Program chaired by Executive Director (Industrial Services).
6.
The 2020 Saudi Aramco
Excellence Awards
Abqaiq Plants Reliability Engineer Gonzalez Quinones, Andres E was
recognized in the 2020 Saudi Aramco Excellence Awards on 29th of December
2020.
7 Abqaiq Plants Restoration Excellence and
Resilience
Abqaiq Plants restoration team was recognized in the 2020 Saudi
Aramco Excellence Awards. Abqaiq plants restoration team are:
- Tamim Dossary
- Saleh Uthman
- Abdullah Dossary
- Abdulrahman Sughayer
- Dakheel Harthi
- Hezab Abbas
- Muhammad Imran
- Azzam Saati
- Fahad Al Osaimi
- Mohammed Assiry
- Hatim Hujaili
- Hussain Al Qahtani
- Abdullah Al Zahrani
9.
Abqaiq Plants/MSSD/W&FS was recognized
by BUREAU VERITAS as 9001- 2015 ISO
Certified till 23/09/2022.
Abqaiq Plants recognized on ISO 9001:2015 for metal fabrication
welding and coating of oil gas pipe and associated structures. This
recognition from the International Organization Standard came
after being recognized to demonstrate the ability to consistently
provide products and services that meet customer and regulatory
requirements and to demonstrate continuous improvement.
10.
Abqaiq Plants Maintenance Department was
recognized by BUREAU VERITAS as 55001-
2014 ISO Certified till 07/12/2022.
Abqaiq Plants was recognized on ISO 55001:2014 Provision of asset
management system related to maintenance activities. The
recognition was obtained after passing all requirement of managing
the lifecycle of assets more effectively. By implementing ISO 55001
Abqaiq plants will have better control over daily activities, achieve
higher return with their assets, and reduce the total cost of risk.
11.
Abqaiq Plants/ T&I was recognized by
BUREAU VERITAS as 9001- 2015 ISO Certified
till 08/11/2023.
T&I Unit recognized ISO 9001:2015 Quality Management System.
This recognition from the International Organization Standard came
following the great efforts from T&I Unit in Abqaiq Plants for being
recognized to demonstrate the ability to consistently provide
products and services that meet customer and regulatory
requirements and to demonstrate continuous improvement