HFL Consulting

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An understanding of how plant condition is changing over time can be used to help plan inspection, maintenance and repair work to make best use of available resources and minimise impact on operations.

Most companies have programmes in place to cover equipment not captured by PSSR but approaches can differ. Some are consequence focused, concentrating only on inspection of major vessels, tanks and other main plant items even though, for example, statistically speaking, pipework is a much more likely release source for hazardous substances.

If this is the case, our team of engineers can help you to build on what you have, to develop a comprehensive inspection programme based on all risks, not just those associated with releases of stored energy or loss of containment from bulk storage systems.

Asset Registration 

We can help to develop a comprehensive inventory of assets covering primary containment systems and supporting structures, and the prevention, control and mitigation safeguards in place. The asset registration process will capture essential details relating to materials of construction, duties, design basis, safe operating limits, allowable tolerances, and so on.

Criticality Studies 

An understanding of potential consequences for people, the environment and the business enables us to prioritise assets for further assessment.

Degradation Study 

We can help to assess the potential for ageing in critical plant and equipment.

RR509 ‘Plant ageing: Management of equipment containing hazardous fluids or pressure’ defines ageing and ageing plant as:

“Ageing is not about how old your equipment is; it is about its condition, and how that is changing over time.  Ageing is the effect whereby a component suffers some form of material deterioration and damage (usually, but not necessarily, associated with time in service) with an increasing likelihood of failure over the lifetime.

…….

The significance of deterioration and damage relates to the potential effect on the equipment’s functionality, availability, reliability and safety.  Just because an item of equipment is old does not necessarily mean that it is significantly deteriorating and damaged.  All types of equipment can be susceptible to ageing mechanisms”.

Our degradation studies consider a range of issues including but not limited to:

  • Operating temperatures and pressures
  • Operating history in relation to design limits
  • Materials or construction
  • Aggressive chemicals (corrosive or abrasive)
  • Environmental conditions
  • Maintenance and inspection history
  • EC&I equipment obsolescence
  • Potential for corrosion under the insulation

We can provide the results of the studies in workbook format, enabling them to be maintained as living documents.

Inspection Planning

We can provide a plant-specific risk assessment grounded in established damage rate data to aid inspection planning. This considers damage caused by ageing, allowing us to determine which areas are most at risk so that you can:

  • Increase the probability of finding damage before failure
  • Reduce the uncertainty and expense associated with low added-value inspections
  • Target budget and resources at plant and machinery most likely to fail
  • Interpret inspection findings to inform future inspections

We can help you to design and implement programmes to deliver tangible improvements in operational practices and performance to improve overall asset integrity and reliability.

Written Schemes of Examination and Legislation

Remnant Life Studies