Case Study

Safely delaying and saving $2 million

Pressure vessel life extension and risk-based inspection scheme


Operator, North America


Process equipment


Estimated cost saving of £2 million

Client Challenge

Our client contracted us to see if the planned turn-around of its pressure vessels could be safely delayed by one to two years and, preferably, if the inspection time could be extended beyond 10 years.

How we helped

We collected data on the pressure vessels and carried out additional, non-intrusive inspections on the high-risk components to keep the risk at acceptable levels. Our investigative work included a comprehensive, risk-based process and corrosion study of the current operation.

We used the risk profile created as a baseline for comparison with alternative inspection schemes. Various turn-around dates and inspection intervals were discussed and analysed in terms of risk and cost savings.

Powerful Results

Based on our work, the client was able to:

  • delay the turn-around by two years
  • extend the pressure vessel internal inspections beyond 10 years
  • still meet the relevant inspection code (API-510).

The estimated cost saving for the client was greater than $2 million, more than 25 times the cost of the project, which was completed in under three months.

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