Thaioil, one of Thailand’s premier integrated petroleum and petrochemical companies, partnered with Cenosco to advance its asset integrity management. By deploying IMS PEI, IMS RCM, and IMS SIS (formerly known as SIFpro), Thaioil achieved significant improvements in:
- Inspection planning and execution
- Preventive maintenance effectiveness
- Functional safety lifecycle management
This business case presents how these three integrated solutions contributed to enhanced safety, cost savings, operational efficiency, and decision-making across Thaioil’s downstream operations.
Background & Business Need
Thaioil manages complex downstream operations that involve high-risk assets and critical safety requirements. The company sought to modernize legacy systems and disjointed workflows across three core areas:
- Inspection: Fragmented systems and manual processes limited visibility and efficiency.
- Maintenance: Planning lacked centralized data and struggled with scope optimization.
- Functional Safety: Risk analysis and SIF management were manual and time-consuming.
Thaioil aimed to transform its operations by adopting a fully digital, integrated, and cloud-based approach for their asset management strategy. The goal was to reduce turnaround, and inspection costs and scope while enhancing the performance of preventive maintenance. At the same time, the company sought to strengthen hazard identification processes and improve safety barrier management. A critical part of this initiative was breaking down data silos that had long existed between inspection, maintenance, and functional safety teams, fostering better collaboration and efficiency across all departments.
Proposed Solution: The IMS Suite
Cenosco’s IMS Suite offered Thaioil three key modules tailored to its needs, providing an integrated, cloud-based solution that addressed inspection, maintenance, and safety in a single platform. This approach aligned with Thaioil’s goal of eliminating data silos, standardizing processes, and enabling better cross-functional collaboration.
IMS PEI:压力设备完整性
The IMS PEI module enhances inspection management and corrosion monitoring through advanced digital tools. Rather than simply replacing manual processes, it introduces smarter, data-driven workflows that optimize integrity operations:
- Our EVA analysis prioritized heat exchanger inspections for cost savings
- Our advanced s-IDAP predictive analysis identified corrosion trends for proactive planning
- Digital inspection test plans for standardized, traceable inspections
- Balanced workloads across routine operations and Maintenance Turnaround cycle.
IMS RCM: Reliability Centered Maintenance
Provided a structured, reliability-based maintenance framework:
- Predefined rotating equipment templates
- Centralized recommendation workflow integrated with SAP.
- Manage Equipment Care (MEC) Optimization boards to optimize scope and reduce PM costs
IMS SIS: Safety Instrumented Systems
Delivered end-to-end lifecycle safety support:
- SIL/LOPA calculations
- CMMS integration for proof test scheduling
- Periodic SIF revisits and enhanced risk controls
These modules were deployed independently but operated on the same cloud platform, creating a unified data and decision environment.
Benefits & Outcomes
Thaioil’s use of IMS PEI, RCM, and SIS delivered measurable and strategic improvements across inspection, maintenance, and safety, while creating a unified digital ecosystem. The benefits fall into four core categories:
Operational Efficiency
- Streamlined Inspection Planning: Digital test plans reduced manual effort, while s-IDAP enabled predictive corrosion planning of their pressure equipment’s and EVA analysis for heat exchangers improved inspection prioritization, leading to faster planning and better resource allocation.
- Accelerated Maintenance Workflows: IMS RCM introduced structured equipment templates and SAP integration, significantly reducing planning time and manual errors.
- Faster Execution Across Functions: With all three modules integrated on a single platform, teams worked from the same data and processes, enabling faster responses to issues like corrosion under insulation (CUI) and more efficient SIF reviews. This shared environment also made cross-functional initiatives between engineering, inspection, and process safety more seamless and effective.
Improved Decision-Making
- Data-Driven Maintenance Strategies: IMS RCM enabled smarter grouping of maintenance activities, and failure analysis, improving reliability KPIs.
- Proactive Safety Management: Regular SIF assessments and automated LOPA/SIL calculations via IMS SIS helped identify and mitigate risks early.
- Unified Insights: With integrated modules, decisions are based on consistent, centralized data—improving alignment across teams on inspection and maintenance activities.
Cost Optimization
- Optimized Inspection Scope: By targeting high-risk areas through predictive tools, IMS PEI enabled Thaioil to reduce inspection scope without compromising asset integrity.
- Maintenance Cost Control: Optimized preventive maintenance plans through IMS RCM reduced over-servicing and supported cost-efficient planning without making compromises.
- Resource Efficiency: Across all systems, automation and integration of data across the otherwise disjointed systems reduced redundancy and freed teams for higher-value work.
Enhanced Risk & Functional Safety Management
- Improved Hazard Identification: SIFpro (predecessor of IMS SIS) enabled systematic reviews of safety barriers and ensured SIL compliance.
- Better Barrier Monitoring: Thaioil can now visualize risk through Bowtie methodology and synchronize safety studies across the SIS lifecycle.
- Audit Readiness: Digital records and centralized revisions in IMS SIS simplified compliance to safety regulations and supported internal and external audits.
Conclusion
Thaioil’s deployment of IMS PEI, IMS RCM, and IMS SIS demonstrates the effectiveness of an integrated approach to asset integrity management. Each module addressed specific operational challenges, but combined, they created a foundation for:
- Safer operations
- Smarter decisions
- 降低成本
- Greater efficiency
This business case supports continued investment and scaling of Cenosco’s IMS Suite across other Thaioil units and potentially other sites in the region.
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