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Case Study

Turnaround integrity support - Fitness for service assessment & repair plan


Major ammonia producer

Asset type

Stripping column



Client challenge

During a turnaround, the client identified significant damage on the internals of the column's pressure boundary. This posed a significant problem for the client as the ability to restart quickly was compromised and could have required extensive repairs resulting in delayed start-up and subsequent loss of production.

How we helped

Vysus helped assess the corrosion and identified Non-Destructive Evaluation (NDE) methods which could quickly and effectively quantify the metal loss, using laser scanning and phased array corrosion mapping. The client was able to quickly capture and quantify the damage which we used to perform an API 579 Level 3 Fitness for service assessment, with quick results. This showed that the vessel could be operated without a repair, even though it was significantly corroded.

Our in-house ASME authorised inspector and repair engineers also simultaneously produced a repair plan for the vessel which followed guidance of the American Society of Mechanical Engineers' ASME Section VIII Div 1, National Board's NB-23 and American Petroleum Institute's API-510, to ensure a quality, code-compliant repair could be achieved, if necessary.

Powerful results

Using the results of the Fitness for service assessment, the client was able to install a corrosion resistant barrier, preventing future corrosion, and was able to defer the repair to a future turnaround. The client is able to effectively plan the repair using the guidance in the repair plan, when the need arises, procuring the necessary materials and personnel.

Subsequently, the client was able to refocus its resources on other emerging repairs and turnaround activities.

The Vysus team was able to respond within 48 hours by performing detailed Level 3 FFS analysis and providing a level of certainty for the operator to resume operations confidently without significant repairs. Timely access to competent and experienced engineering personnel using advanced technical finite element software can provide prompt confidence to operators to make informed decisions to repair, replace or postpone action.

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