Challenge

The objective was to enhance the inspection organization and strengthen existing mechanical integrity programs to proactively reduce leaks and maintain safe, reliable operations. This involved optimizing inspection processes, improving data quality, and ensuring timely identification and mitigation of potential failures. By building a more robust and efficient integrity management framework, we aimed to ensure long-term sustainability and regulatory compliance across all assets.

Solution

Valdes Architecture & Engineering staff reviewed and improved the mechanical integrity work processes, including the interactions between Operations, Inspection, Maintenance, Engineering and Turnarounds. The Inspection Organization was enhanced to include fully integrated risk-based inspection (RBI) and fitness for service (FFS) engineering assessment capability, which improved the speed and quality of their work. The RBI and FFS programs were made more robust by developing Corrosion Control Documents and Integrity Operating Windows as per API RP 970 and 584 respectively. Corrosion under insulation, corrosion under fireproofing, and vibrating line programs were also implemented, including training on how to prevent or mitigate damage and keep these programs sustainable.

Impact

Within three years the integrity programs helped this site achieve and maintain zero overdue inspections, increased the inspection finding rate from 4% to 24%, reduced through-wall corrosion related leaks from 32 per quarter down to two, and increased overall availability by 4%, which equated to over $5 million in margins.

Services

Maintenance, Reliability & Asset Integrity