Pre-Start-Up Leak Risk Management

 

Quick Response to remote locations. 

Once again AIS mobilised on very short notice to perform a Nitrogen purge & pre-start-up leak Risk Management survey of a potentially hazardous gas processing plant located in a very remote part of Australia

 

AIS contributed to an “all hands on deck” effort to get the process plant back online safely. 

 

Objective. 

The hazardous nature of the process required a pressure integrity verification of all process components through a pre-start-up nitrogen gas leak survey of the affected process unit.

 

Work Scope & Methodology

AIS deployed ultrasonic emissions scanning technology to survey all potential gas leak sources to atmosphere and passing valves to flare from internal leaks across closed valves. 

Ultrasonic emissions scanning enables detection of leaks from process components that cannot be “taped & pin-holed” as with traditional leak checks.

In addition to typical flange leaks, we also detect inert or hydrocarbon leaks from instrument fittings, threaded connections, couplings, valve glands. Essentially any potential leak source that may or may not have been disturbed through maintenance activity.

 

Challenges

Time

Portable, highly sensitive technology, experienced personnel and proven survey methods enabled AIS to survey the plant and get the job done with minimal fuss as part of an around the clock Inspection and test plan schedule.

No time was wasted taping and pin-holing flanges.

The ITP progressed from gross leak check to process pressure checks in one shift.

 

Access

Potential leak sources surveyed included all process components at grade and in hard-to-reach locations requiring Working at Height elevated work platform equipment.

 

All leak sources. 

The hazardous nature of the process gas under normal operating conditions required a ZERO LEAK policy. 

This required detection and pre-start-up remediation of the smallest leaks from all potential leak sources including process gas and instrument tube and fitting components. 

 

Collaboration. 

AIS engaged with the client’s static and rotary process integrity teams, operations team and maintenance team. 

Wefollowed a staged pressurisation inspection and test plan (ITP) verifying process integrity at sequential hold point pressures. 

We worked with our client to risk assess, prioritise and resolve a number of opportunities for improvement at ITP hold points before proceeding to higher pressures. 

 

The bottom line. 

AIS is proud to have played a small but very important part in enabling our client on their journey toward a safe plant re-start and a sustainable cost effective long term Leak Risk Management (LRM) program. 

 

Questions worth asking. 

• Do you have an accurate and up-to-date picture of your gas process integrity risks, where they are located and their current status ? 

• Can you visually communicate this status and risk to senior management or the regulator ? 

• Can you visually collaborate with remotely located personnel to perform repair action prioritisations and risk management of known leaks awaiting shut-down delayed repair action ? 

• Is it time to contact AIS for a no-obligation confidential discussion about the integrity of your current leak risk management program ?  

 

Find out more at www.aissoz.com or call us on +61(0)488 659 598