Case Study
Future-Ready Mechanical Integrity Program: Harnessing Contextualization and 3D Visualization
Client: Fertilizer Plant
Our client was facing challenges with their time-based Mechanical Integrity program, which leveraged inspection methods that were failing to target critical damage mechanisms and susceptible areas. Additionally, their existing Integrity Data Management Systems (IDMS) was hindered by outdated, incomplete data and poor user adoption. Compounding these issues, inspection isometrics were minimal, and P&IDs remain outdated, leading to inefficiencies in inspection planning and execution.
Our Solution
- Developed Asset 3D Visualization using a combination of laser scanning, high-resolution imaging, and 3D modeling to develop an accurate representation of their facility, which was used to validate equipment lists and generate inspection isometrics.
- Created Corrosion Loops to group equipment and piping into similar damage mechanisms.
- Conducted a Damage Mechanism Review to identify and validate anticipated damage mechanisms per asset with site personnel.
- Created CCDs and IOWs to provide an overview of how and why the asset experiences damage and recommend actions to mitigate, monitor and manage the risk of loss of containment.
- Delivered Enhanced Inspection Plans by targeting inspection methods based on how the equipment is being damaged and implementing Risk-Based Inspection where appropriate.
- Updated the IDMS with the validated equipment list, corrosion loops, damage mechanisms, and inspection plans.
- Integrated and Contextualized Integrity Data into the 3D model, including RBI risk results, corrosion loops, deadlegs, amongst other data to allow a visual, data-driven mechanical integrity program.
The Benefits
- Optimized and Focused Inspection Efforts through inspection plans that leverage the right inspection method, correct area, and optimized frequency.
- Improved Risk Management by equipping the client with CCDs, IOWs, updated IDMS, and 3D Visualization.
- Optimized Operating Workflows and Planning through visual data-driven decisions that reduces unnecessary field trips
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