This article features a discussion of three of the key elements to sustain and improve your mechanical integrity program successfully.

Safety and reliability should not be at odds with one another; in fact, they contribute to one another’s success.

A look at the three types of fixed equipment mechanical integrity (FEMI) decision-makers you can encounter, along with the differences in the effectiveness of each.

A look at common reliability issues to help give perspective on where issues may be waiting and how to handle them when they arise.

Maintaining the longevity and success of a reliability program requires evergreening, a continuous effort to keep processes up-to-date and relevant.

Auto-refrigeration can impose low temperatures onto process vessels and piping causing them to be at risk of brittle fracture, the sudden break-before leak phenomena that can result in catastrophic rupture of the equipment.

While data science has the power to revolutionize the reliability industry, it will only do so with strong guidance from SMEs. This combination enables facilities to develop solutions to challenges based on each method’s unique strengths.

A case study on utilizing the Quantitative Reliability Optimization (QRO) methodology to help better evaluate equipment risk and predict future product availability.

Of the nearly 70 damage mechanisms listed in the latest edition of API RP 571, the highest FEMI risk may be the ones that are highly localized in nature and, therefore, the hardest to find.

Every year, Inspectioneering hosts a private meeting to glean insights, feedback, and guidance from our Editorial Board members. This time around we posed several questions, with responses to each summarized in this note from our chief editor.

An approach such as LVC can help enhance API 581 POF calculations for thinning. This method has proven to increase accuracy, precision, and has the flexibility to handle one-off cases that are handled manually today.

Equity Engineering Practices® (EEPs) are a collection of design and maintenance focused corporate standards that include >850 engineering standards, and >300 piping classes. Enhance your mechanical integrity programs, improve equipment...

There is a major difference between fixed equipment mechanical integrity (FEMI) and fixed equipment reliability (FER). It’s important to differentiate between the purpose and reasons for the two programs even when they are often mixed together.

Inspectioneering and Pinnacle co-hosted the 8th bi-annual Meeting of the Minds with a select group of mechanical integrity experts from across the industry. The meeting focused on major projects in equipment integrity and reliability.

A historical review into the integrity of reformer furnaces since commissioning is discussed in this case study, along with other technical and engineering challenges, and the efforts to overcome them.

Utilizing a risk assessment methodology to determine the amount of detail in our QA/QC plans, as well as who needs to be involved, may help us improve both the effectiveness and the efficiency of our QA/QC work process.

This article is Part 2 in a series discussing condition monitoring optimization where statistical inference techniques on the measured data can be utilized to provide reasonable expectations regarding the true extent of damage on the asset.

Training options to meet your needs. E²G contracts with API to deliver training programs for FFS, Risk–Based Inspection, Damage Mechanisms, and Pressure Relieving Systems. ETI and Customized Training offers specialized courses based on industry...

The positive impact of digital twins on planning, costs, turnaround, revenue generation, and safety are substantial and rapid in their return. This article will examine why to leverage this technology and how to do so in a fiscally viable manner.

Condition monitoring optimization goes beyond traditional CML optimization, which is often limited in the breadth of analysis, or can overemphasize a subset of the overall objective.

This article discusses making continuous improvements in your fixed equipment mechanical integrity work process using the Plan-Execute-Review-Improve (PERI) model.

The results of the analysis demonstrate the exciting possibilities for how “Big Data” can be used to empower the reliability and corrosion engineer to solve real-world reliability challenges faster and more accurately than current industry...

Acting as a reliability twin, QRO is a new dynamic reliability approach that bridges existing first principles-based reliability models with advanced data science principles and system-based optimization to drive improved facility performance.

In today's chemical and refining industries, sustained long term reliability of facilities is critical to profitability and competitiveness. In fact, history shows that differences in operating expenses between best-in-class refineries, and poor...

This article discusses how composite materials can be used to mitigate light CUI damage and/or repair and restore structural strength to the affected piping system.

Quantifying corrosion for different crude fractions allows planners the ability to mix and match crude blends alternatively to achieve pre-set metal loss and reliability goals. This flexibility has significant implications for extensive cost savings.

This article examines the quantitative tank RBI method found in API 581 and discusses uses for tank RBI other than deferral of scheduled internal inspections.

A risk management approach for relief valves should be able to determine the proper interval of maintenance events and the necessity of installing isolation valves, rupture discs, or 100% spare capacity.

The article discusses how allowing ‘normalization of deviance’ to occur in the workplace raises our organizations’ risk threshold in an uncontrolled and unmanaged way.

Are you truly prepared for your next Turnaround? Effective work processes are required to successfully plan, manage, review and supervise plant turnarounds. Inspection planning and work scope selection are critical aspects of any turnaround...

While collecting more data may seem like the solution, the key to successfully forecasting system availability is building a strong program based on existing data. This can be accomplished through Quantitative Reliability Optimization (QRO).

This article describes an owner-user’s evergreening process to maintain accurate data to support the mechanical integrity program and assist in planning inspections, turnarounds, repairs, replacements, and upgrades.

This article discusses how Quantitative Reliability Optimization (QRO) can help empower reliability and operations leaders with better data to make smarter and more confident reliability decisions for their facilities.

As the industry continues to collect more data, many facilities are unable to confidently leverage it to drive better reliability decisions because they do not collect the correct type or amount of data, which leads to unknown risks.

This is the first article in a new column. In each article, the author will explore how different parts of organizations can partner to discover new efficiencies, improved equipment integrity, and opportunities to capture additional margin.

TEAM’s integrated touch point corrosion program manages all aspects of the integrity process from screening for damage to permanent repair assuring integrity – every time. TEAM’s unique turn-key approach to touch point corrosion integrity...

The manner by which reliability is achieved is experiencing a much-needed paradigm shift in the way it uses data. In this article, we’ll explain how you can leverage this industry shift to implement data-driven reliability at your facility.

The first two parts of this series covered the basics of fracture mechanics and how the FAD is interpreted. This article touches on a few practical points regarding the application of fracture mechanics in a plant environment.

Restoring process piping within a short time frame requires an innovative approach. This article discusses how a repair using composite materials proved to be successful and enabled a quick return to operations.

Every fitness-for-service (FFS) assessment must have a well-defined acceptance criterion. For many damage mechanisms, it’s the “remaining strength factor” (RSF). But for crack-like flaw assessment, it’s the Failure Assessment Diagram, or FAD.

Facilities that can successfully leverage both their data and expertise while effectively integrating this unified model into their core business processes can improve performance and eliminate non-value-added activities.

Pinnacle's data-driven reliability framework ensures the right data is fueling the right intelligence, helping you make confident, strategic decisions.

Fracture mechanics is a branch of engineering that describes the behavior of cracks – how they grow and when they fracture. Fracture of cracks is particularly dangerous because it can happen without warning under normal operating conditions.

This article presents a methodology for calculating and understanding how many qualified API inspectors you need to staff in order to improve fixed equipment mechanical integrity and reliability at your operating site.

This article discusses some of the common roles of the RBI team and provides a glimpse of an RBI program gap assessment, while offering helpful advice for improvement.

Understanding asset integrity and its management framework is important to sustaining the integrity of assets in the oil and gas industry. This article will discuss eleven primary elements that make up an asset integrity management program.

Inspectioneering and Pinnacle co-hosted their 6th bi-annual Meeting of the Minds roundtable discussion earlier this year. This meeting’s focus was on how Covid-19 and the decline in oil prices have affected MI programs across the industry.

Download Pinnacle's Economics of Reliability Report - Refining to see how reliability is affecting profitability.

This article presents a model to better predict the corrosivity of hot crude oil streams, which is based on open literature going back for almost 60 years and incorporates published information from joint industry projects (JIPs).

Inspectioneering had the opportunity to catch up with David Clark of Lloyd’s Register after his keynote presentation at the 2020 International Pressure Equipment Integrity Association (IPEIA) conference in Banff, Canada.

This article presents a comprehensive integrity management program for catalyst tubes, including elements on monitoring, inspection, data analysis, remaining life assessment, and control of human factors.

The Journal was launched in 1995 with the core mission of helping the fixed equipment reliability community perform their jobs more effectively by arming them with information to better understand and apply available technologies and methodologies.

This article introduces the P-F Interval and its importance in predictive maintenance, describes methods to detect failures early, and maps out a path to begin an effective Predictive Maintenance program at one’s facility.

Traditional, paper-based inspection processes can prevent plants from being as effective as they can be. By digitalizing your mechanical integrity process and data with MISTRAS Digital®, plants have realized up to 75% gains in IDMS data entry and...

This article wraps up the three part series by combining management systems to work towards the ultimate goal of achieving a defect-free operation in process plants.

Today's operators are implementing a myriad of Mechanical Integrity and Reliability programs to realize greater results from their facilities. However, for each of these programs to be effective, they must be fueled by quality and up-to-date data.

I have been involved with risk-based inspection and risk-based work process development for much of my career. The one thing I have learned as I’ve walked this path is that the concept of ‘risk’ extends far beyond our industry.

Much like the equipment and piping they support, structures should be part of a comparable structural integrity (SI) program. This article will examine key components of a comprehensive SI program as an essential companion to an MI program.

Developing a comprehensive turnaround (TA) work scope for process equipment is a critical step for achieving a facility's business goals. Risk Based Work Selection is a proven process for prioritizing and optimizing planned work for an impending TA.

The OmniScan™ X3 64 phased array and TFM flaw detector is equipped with enhanced phased capabilities and even faster TFM. The rugged and portable instrument features powerful 64-element probes with a 128-aperture TFM.

Risk Based Work Selection (RBWS) is an industry best practice used to help refiners better-manage the safety and reliability of operations for a facility. When properly conducted, RBWS can help refiners optimize major turnaround projects.

This article provides a case study showing the real costs and effects of having a dated engineering standards program, as well as the financial benefits through increased reliability of having a thriving engineering standards program.

According to industry experts, particle contamination in lubricants is the number one cause of lubricant-related equipment failure. Fortunately, there are steps operators can take to reduce contamination and increase the service life of equipment.

This article describes some strategies owner/users can implement to reduce failure rates, eliminate wasteful activities, reduce costs, increase capacity, improve safety, and achieve the goal of defect-free operations.

This article provides a summary of the 2019 API Inspection & MI Summit keynote address, which offers a past, present, and future outlook on fixed equipment mechanical integrity from an industry professional with 50+ years of experience.

The bp refinery in Rotterdam was able to establish a continuous digital inspection process for the first time by using the DIMATE PACS – including the digital evaluation and transmission of quality-assured inspection data to the RBI.

A quest for a defect-free operation requires an effort to systematically reduce the current equipment failure rates. This series proposes a newer, leaner way of thinking to help discover and eliminate conditions that may lead to defects.

An effective RBI system implementation results in, not only safeguarding your assets & people, but can also reduce unnecessary inspection activities that may be required due to conventional & nonsystematic approaches.

The 2019 API Inspection and Mechanical Integrity Summit will be kicking off later this month in Galveston, TX. This four-day event will begin with 14 high level training courses offered Monday, January 28th, and then a top notch conference and...

This article discussed the importance of an asset management philosophy that integrates software, maintenance tools (RCM, FMECA, RBI, PM, and PdM), data collection, and analytics to improve and optimize asset management through emerging technologies...

This article provides an overview of the key components in establishing IOWs, the levels of IOW limits, and the basic principles and application of API Recommended Practice 584 to achieve reliable fired heater performance.

Whether you decide for a Computed Radiography scanner with flexible imaging plates or a flat panel detector with the fastest imaging, or even combine the advantages of both technologies, DÜRR NDT's innovative systems offer high reliability and...

This article walks you through a three-step approach, while providing different scenarios, for identifying and proving the value of reliability improvement initiatives.

The most valuable unit of measure within a turnaround is not money, but time. Successful turnaround planners are now integrating the Detailed Inspection Planner (DIP) within their teams to increase the accuracy of planning and reduce the time...

As assets age and production demands grow, it becomes increasingly critical to implement sustainable long-term AIM strategies and programs. This article dives into the elements that will help ensure the successful management of assets throughout...

This article intends to use a top-down approach of describing RBI methodology and how it fits in a facility management system. The main idea of this article is to provide a comprehensive picture of RBI methodology in terms of basics, technology...

This article is designed to help the reader better communicate their FEMI Mission, Vision, Core Values and Responsibilities to all stakeholders at their site.

Traditional inspection methods used to detect internal corrosion and corrosion under insulation (CUI) in piping and pipeline assets can be time-consuming and costly. With ART, you’ll discover CUI detection best practices that can help save you up...

Last November, Inspectioneering and PinnacleART hosted a roundtable discussion for a select group of leading mechanical integrity experts. This forum explored how the MI field will have to prepare for the impending loss of knowledge resulting from...

Infrared (IR) thermometry has been used for over forty years to monitor tube metal temperatures in refining and chemical furnaces. Recently, IR thermometry has been criticized in the industry for delivering inaccurate readings; however, this is...

In this exclusive interview, you’ll hear from Eddie Acosta, Reliability Manager at Placid Refining. During our discussion, he shared some of their challenges, strategies, and a transparent glimpse into some the real issues in his 82,000 bpd...

APM implementation is anything but a pain-free process. Blame tends to fall on vendors, but there are oftentimes activities that do not get completed that tend to have a larger effect on the success of implementation. This article addresses some of...

3 common repair scenarios include routine maintenance, scope repairs, and major discoveries. An inspector’s ability to properly manage each situation can mean the difference between mechanical integrity success and failure.

With class-leading thermal performance, superior CUI defense, and complimentary engineering support, our aerogel insulation solutions are a top choice in helping facilities drive energy efficiency, improve safety, increase yields, and reduce downtime

Most plants have pieces of equipment with chronic problems that impact profitability due to the frequency of outages, cost of repairs, and lost production. It is critical that specific actions are taken to identify and eliminate these “Bad...

Risk is an inherent aspect of asset management. Unfortunately, controlling it is easier said than done. Risk must be managed beginning with the initiation of a project and lasting until completion. How can one implement a reliable risk management...

The Valve World Americas Conference provides an opportunity for people from all sides of the flow control industry to come together to discuss experiences, share insights and work together to resolve common challenges. Sharing knowledge and...

Inspectioneering Founder & Chief Editor, Greg Alvarado, recently had the privilege to sit down with Clay White, Director of Mechanical Integrity for Phillips 66 (Downstream), to discuss the world of fixed equipment reliability in the refining and...

Integrity Operating Windows (IOWs) have a subset of operating variables that are important for degradation monitoring, but may not have direct operational controls. Per API RP 584 Integrity Operating Windows, these are known as IOW Informational...

Inspectioneering recently had the opportunity to sit down and chat with Cary Forgeron and Samuel Fisher about the importance of oil analysis to effectively managing the reliability of rotating equipment used in the the O&G and other processing...

This article covers where to start, what to look for, and how to execute a data and systems-focused performance improvement project that can drive large overhead savings.

This article presents a perspective on the human factor and emphasizes the value of using risk tools at all levels in the organization to help provide management focus during times of severe economic pressure.

Integrity and reliability personnel at processing facilities are no strangers to initiatives to improve processes in the pursuit of establishing best-in-class reliability programs. It is common practice for operators to enlist help from third...

Achieving fired heater reliability in conjunction with meeting performance standards can be a challenging feat. Performance is a measure of the degree to which the fired heater is in an operable condition at any given time.

Inspectioneering recently had an opportunity to sit down with Walt Sanford, President and COO of Pinnacle Advanced Reliability Technologies, and discuss what Reliability means to his clients and others in our industry. We hope you find the exchange...

Equipment integrity and reliability programs are essential for refinery and chemical facility operators. The processes of the programs are developed to ensure safety, optimize component life cycles, and promote smooth and economical operations.

This article highlights several benefits of sound reliability and mechanical integrity practices and how they serve as the cornerstone of effective asset management. Moreover, we believe effective asset integrity management is not only important,...

Inspectioneering recently had the opportunity to sit down and chat with Brian Fahnestock about heat exchanger issues in the refining and petrochemical sectors and how temporary solutions can help mitigate the damage should a problem arise.

Inspectioneering recently had the opportunity to sit down with Texas Railroad Commissioner Ryan Sitton and discuss the evolution of reliability in the oil and gas industry.

Operators in all industries are trying to increase equipment availability, yet oftentimes critical process equipment is not available due to planned or unplanned maintenance. To increase equipment availability, steps must be taken to reduce...

Today, many managers are finding that they can address the reliability of all types of assets by combining RBI and Reliability Centered Maintenance (RCM) processes together into one comprehensive reliability management process.

Reliability engineering tools and concepts can be used to avoid or delay failures, thus increasing product service life. Design or maintenance teams use reliability engineering techniques to identify failures and their causes.

In 2013 Inspectioneering published content covering a wide array of topics, from risk-based inspection, to advanced nondestructive testing methods, to pipeline integrity management systems. Last year, we published more content than any year prior;...

Risk Based Integrity Management (RBIM) is the latest process for developing strategies to properly operate and maintain a manufacturing or production facility in the Oil, Gas, and Petrochemical Industry (OG&P). RBIM is a significant change from...

As the technology of NDT systems improve, it is important to assure that the people and processes using this technology are adequately prepared in order to take full advantage of the enhancements of the system.

This series of articles describes the elements for a successful fixed equipment reliability program in a petrochemical facility. These articles will address management systems, engineering practices, preventive/predictive maintenance/inspection...

This series of articles describes the elements for a successful fixed equipment reliability program in a petrochemical facility. These articles will address management systems, engineering practices, preventive/predictive maintenance/inspection...

The following is the final part of a 2-part series outlining the relationship between key operating parameters and corrosion that has been used to develop a set of guidelines to define an operating envelope.

Corrosion and fouling in HF Alkylation Units are closely linked to feed quality and operating conditions. This article outlines the relationship between key operating parameters and corrosion that has been used to develop a set of guidelines to...

In part 1 of this article we covered the importance of quality assurance of UT data, that is, understanding for each particular application, the accuracy required of the UT data, and new ways/graphical program to analyze and show the...

This is Part II of a series of reliability of coke drums. Part I discussed some of the causes of bulging and cracking in coke drums. Here, the effect of operation on damage will be covered, along with possible solutions for increasing drum life...

Petroleum coke production is an important source of revenue for many refineries. While coking units were initially constructed to deal with a waste product, these units are now of significant economic value.

In the aging portion of an asset's life, the failure rate is exponential. This creates a need for predictive maintenance expenditures to maintain reliability.