Case studies

Flag_of_Australia_39x24.png Integrity and maintenance build for INPEX, Australia

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Client: INPEX

Project value: AUD $19.4m

Assets: Ichthys Offshore FPSO, CPF, GEP, Onshore LNG Facilities

Location: Offshore Western Australia and Onshore Northern Territories


Project summary

March 2015

Start date

May 2017

End date


Ichthys represents the largest discovery of hydrocarbon liquids in Australia in 40 years, involving some of the biggest offshore facilities in the industry, a state-of-the-art onshore processing facility and an 890 km pipeline, uniting them for an operational life of at least 40 years.

In 2015, Petrofac was awarded a contract to develop an integrity and maintenance programme for INPEX’s Ichthys Project, targeted for completion six months ahead of commissioning.

A global effort

In our largest integrity and maintenance programme build to date, we spent 139,000 man hours, engaging more than 120 staff from across Petrofac’s UAE, UK, USA, Australia and India offices.

The team initially defined an integrity and maintenance build road map of activities to deliver the required programme and carried out front end strategy reviews and revisions to ensure the success of the build.

Specifically, the work entailed the development of an asset hierarchy with approx. 550,000 individual tags across the:

  • Central processing facility (CPF)
  • Offshore floating production, storage and offloading (FPSO) vessel
  • Onshore liquefied natural gas (LNG) facilities including the combined cycle power plant (CCPP)
  • Subsea umbilicals, risers and flow lines (SURF)

In addition, more than six million data attributes were collected to support the maintenance and sparing strategy decision processes employed during the programme build.

The planned maintenance programme required:

  • 82 strategies for availability assurance (SAA) and associated maintenance work instructions (MWI) to be developed to cover the entire asset population
  • More than 66,000 material items were cleansed and catalogued in the development of over 280,000 asset bill of materials (BoM)
  • A risk based inspection analysis of the CCPP
  • Development of almost 3,000 written schemes of examination including associated inspection drawings to support the wider risk based inspection programme

Petrofac’s in-house BuildME™ asset management programme development platform was used to provide a fully integrated work management system build environment. It served as a single instance for integrity, maintenance and sparing strategy implementation, thereby offering cost-effective, time-efficient, auditable development and flexible delivery of our asset management services and methodologies.

We delivered a fully integrated, sustainable integrity and maintenance programme, fully aligned with the pre-operational requirements.

Setting INPEX up for future success

As a result of our efforts INPEX have access to easily upgradable evergreen strategies that ensure the maintenance build can be continually refined and improved based upon operational experience.

Subsequently, INPEX is now able to demonstrate to Australian Government Regulatory bodies that the required levels of technical integrity and safety can be achieved and maintained, prior to commissioning the assets.

We continue to work with INPEX through follow-on support to operations and engineering teams including on-going maintenance optimisation and helping assure INPEX operations are positioned for success over the next 40 years of the Ichthys Project.