Mechanical Integrity Case Studies
INTRODUCTION
Since its founding in 2000, SEMPCheck has continued to develop solutions designed to mitigate the inherent risks surrounding the production, transportation and refinement of volatile organic compounds.
SEMPCheck service offerings conceptually integrate operational best practices and leading leak detection technologies into process safety management protocols; creating a more safe and environmentally efficient workplace.
Clients have the ability to remotely manage the integrity of their facilities, to reduce the probability of undetected loss of containment and to increase the overall effectiveness of their critical process equipment.
SEMPCheck Technicians have over 100,000 hours of combined infrared experience and over 75 years of combined petrochemical industry experience. All are certified ASNT Level I and II with a Corporate Level III on staff.
SEMPCheck’s mobile inspection equipment is regularly tested, inspected and maintained in a manner consistent with manufacturer’s recommendations and industry standards. Life cycle records are kept on all equipment.
The infrared cameras deployed are independently tested and deemed compliant with the EPA’s NSPS 40 CFR Part 60 and subpart OOOOa sensitivity standards for optical gas imaging equipment.
These certifications along with SEMPCheck’s experienced ASNT Certified Thermographers affords piece of mind that inspection data gathered is of the highest accuracy.
Video still of gas flow through a vent
Infrared image of sediment in atmospheric vessel
The benefits of conducting a survey include the ability to verify proper operation of production equipment efficiently and safely as well as detect other sources of lost production revenue from fugitive emissions and internally leaking valves such as PSVs. Our surveys also verify proper operation of rotating equipment and detect tank levels to provide data on fluid interfaces and possible sludge/sand.
CASE STUDY HIGHLIGHTS
● Multiple Clients – Incorporated into commissioning process of multiple, innovative deep-water oil and gas production facilities as well as a major LNG export facility. Conducted Infrared/Leak Detection/Acoustic Emission inspections of the entire complexes to identify anomalies during start up process. Incorporated our inspection protocols which resulted in a more efficient commissioning process thereby reducing overall start-up costs significantly.
●Multiple Clients -- We have conducted over 1,000 total site inspections across the United States to assist clients in complying with the EPA greenhouse gas monitoring reporting rule (Subpart W), OOOOa NSPS and state permit requirements. Completed these inspections consistently under budget and on schedule despite challenges faced by weather and logistics.
● Major LNG Export Company – Assisted client with developing a tank repair leak test process that was accepted by DOT utilizing CO2 injection into a LNG storage tank and inspecting entirety of lower structure with infrared cameras that are capable of detecting CO2 gas at a concentration of 3‐4% by volume. Client was able to return tank to operational status as a result of this verification process.
● Major Deepwater Producer– Assisted client in developing mechanical integrity protocols that include three (3) distinct inspection criteria. The first inspection criteria is the Fugitive Gas Leak Inspection. All equipment and components that are in gas service or could have pressurized gas as part of their normal operations are scanned with advanced infrared cameras. The second inspection criteria is the Mechanical Infrared Inspection. All mechanical equipment is inspected with a traditional Infrared camera and all anomalies documented by component with both infrared and non-infrared pictures maintained in a proprietary database. The third inspection aspect is the Valve and Compressor Measurement Inspection whereby rod packing and vent emissions from reciprocating compressors may be measured with calibrated bags or Hi Flow meters, at the clients’ direction. Additionally, valves are screened for leakage utilizing a combination of Acoustic Emission (AE) devices and conventional infrared cameras. Safety hazards not previously identified (such as unseen emissions of flammable gases near hot work operations) resulted in a modification of work procedures ensuring a safer work environment.
● Multiple Clients – Identified numerous atmospheric tank emissions prior to MMS/BSEE inspections which allowed operator to make necessary repairs and avoid costly incidents of non-compliance.
● Major LNG Export Company – Assisted client with developing a strategy to monitor thermal oxidizer external skin temperatures utilizing infrared cameras to avoid a costly shutdown and allow continued safe operations of liquefaction trains.
● Major Gulf of Mexico Producer – Conducted infrared survey of vessels across multiple assets to ascertain internal sediment levels so that cleaning could be scheduled at the most efficient time to minimize unscheduled downtime.