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Oil & Gas

Crude and coker turnaround CML baseline

2026-09-10 · Pressure vessels & process piping (API 510 / API 570)

Measured outcomeDiscovery work entered turnaround scope on the shift it was found, with zero post-outage spreadsheet reconciliation.

A multi-unit Gulf Coast refinery preparing for a crude and delayed-coker turnaround had its mechanical integrity history split across three places: an office IDMS holding legacy thickness tables, contractor ultrasonic spreadsheets from the previous outage, and a separate turnaround scheduling workbook.

Every scope challenge required an engineer to open all three files, verify whether a circuit's short-term or long-term corrosion rate governed, and check whether open recommendations from the prior cycle had been closed.

Current state before intelliSPEC

  • Disconnected CML history: Ultrasonic readings arrived from inspection contractors as weekly Excel sheets and PDFs, requiring manual re-keying into the equipment record after the unit was already back online.
  • Blind spots during discovery work: When internal visual inspection found tray-support cracking or localized shell thinning, the finding sat in a shift email chain before reaching the turnaround planner.
  • Post-outage baseline backlog: Resetting remaining-life calculations and next inspection dates under API 510 and API 570 took months after startup.

Configured path

The site deployed intelliVISION as the single equipment and circuit register, paired with intelliEDGE on field tablets, intelliINSPECT, intelliNDT, intelliINTEGRITY, and intelliPROJECTS.

  1. Register and CML migration: Existing vessel tags, piping circuits, and historical UT readings were imported and deduplicated into , preserving short-term, long-term, and governing corrosion rates.
  2. Offline execution in the unit: Field inspectors and NDE crews checked out assigned work packages in , capturing internal visual findings by voice and streaming UT thickness readings directly to the CML without network signal inside the coker structure.
  3. Live screening and gate control: Readings below triggered API 579-1 Part 4 Level 1 screening in and routed approved repair scope directly onto the wall chart.

Measured outcome

  • Same-shift discovery routing: Emergent findings moved from the vessel manway into scored turnaround scope on the same shift, with photo evidence, CML history, and code basis attached.
  • Baseline closed at startup: Because every reading and ASME PCC-2 repair was signed against the asset record during execution, API 510 and API 570 intervals were current on day one of operations.
  • Audit-ready PSM package: The OSHA 29 CFR 1910.119(j) mechanical integrity trail exported directly from the record without post-turnaround binder assembly.