The challenge
The operator's time-based inspection plan was consuming shutdown time on low-risk equipment while several high-consequence vessels showed thinning and cracking that needed engineering justification to remain in service.
Our approach
We built the RBI database, assessed damage mechanisms and consequences for each item, and produced a risk-ranked inspection plan. For 27 flagged items we performed Level 2 and Level 3 API 579 assessments including FEA of local thin areas and crack-like flaws, supported by PAUT and TOFD inspection data.
The outcome
Inspection scope in the next turnaround fell by roughly a third while coverage of high-risk items increased. All 27 assessed items were justified for continued operation or re-rated with documented limits, avoiding unplanned replacements.
Representative engagement. Client identity and certain project details are withheld or generalised under confidentiality agreements.