Learn how we helped a petrochemical facility reduce the number of Loss of Primary Containment (LOPC) failures by implementing a Risk-Based Inspection and Evergreening program.
A large producer of polyurethane chemicals in North America creates materials for various industries, including the automotive, construction, and aerospace sectors. The facility has specific production objectives focused on efficiently delivering high-quality products to its customers while maintaining availability. To meet these objectives, the facility identified a need to implement a robust Mechanical Integrity (MI) program that would provide a long-term, cost-effective way to manage its assets.
Pinnacle was brought in as a strategic to develop and implement a proactive Risk-Based Inspection (RBI) and inspection program for the site’s fixed equipment. Pinnacle created a multi-year, four-phase implementation plan which included Inspection Data Management Software (IDMS) selection and implementation, RBI analysis, evergreening, and RBI revalidations. The goal of these strategies was to help the facility efficiently manage its operating risks.
Additional elements of Pinnacle’s solution included field drafting, an embedded inspection team to support planned and unplanned inspections, and several special emphasis projects.
The site split its assets into two groups, one for what it deemed critical and one for non-critical equipment. These categories were determined by the Environmental, Health, and Safety (EHS) impact that asset or circuit had if it failed. Over the years of implementation, the benefits started to become apparent. Using failure reports to track the impact, between 2013 and 2020, the site saw a 72% reduction in critical failures and a 48% reduction in non-critical failures, with an overall site failure reduction of 62%. When multiplied by the average cost per type of failure (critical vs non-critical), there is upwards of $500MM in value over that seven-year span that could be attributed to the improvements in the facility’s MI program.