Enhanced Operational Integrity Management Via Digital Twin

Abstract

During the early stages of the Covid pandemic, the oil and gas industry was faced with significant challenges in executing inspections for ageing offshore oil and gas infrastructure together with the management of various operational integrity threats. These challenges were addressed through the collaborative development of remote, digital techniques to minimise inspector time offshore and maximise efficiency. This initially involved a review and challenge of our existing operational integrity management lifecycle, comprising systems data, risk-based strategy development, inspection planning, inspection execution, data management, anomaly management (including fabric maintenance and engineering repairs) and close-out. Working with our partner, GDi, we sought to drive a step change into digital integrity management, combined with streamlined workflows, activities, and administrative tasks. The pilot development involved comprehensive laser scanning of a floating production storage and offloading (FPSO) facility to generate a dimensionally accurate digital twin, overlayed with 360° HD photogrammetry to provide a thorough baseline for subsequent general visual inspections of pressure equipment, piping systems and structural elements. General visual inspections can now be executed remotely, without the requirement for an offshore inspector. The digital twin environment also supported transformation of inspector-led activities, through optimisation of processes, digital inspection workflows via tablets and seamless integration with the integrity management platform. The pilot development also involved enhancing the anomaly risk management process, including management of mitigations (such as temporary repairs) and actions required to resolve and close anomalies. For the anomaly actions, the digital twin environment enables the accurate estimation of fabric maintenance scopes and dimensionally accurate repairs for corrective work orders. The system also facilitates a unique overview of cumulative risk via the plotting of anomalies in the digital twin space. The digitally enhanced operational integrity management system has substantially reduced direct costs and personnel safety risks, enabled substantial improvements in productivity (up to 200% for inspections), and improved the quality of integrity management outcomes.