Client
Food Manufacturing
Asset
Pressure vessels and piping
Location
North America
Client challenge
A national food manufacturing in North America with more than 150 processing facilities across the USA and Canada required a comprehensive and compliant integrity programme to unify their operations.
The age of the facilities varied widely, with some sites having been in operation for up to 60 years. A standardised approach was required to reduce inspection times, improve the quality of these checks, and minimise unplanned downtime across this broad portfolio of assets.
How we helped
Our team implemented a robust Mechanical Integrity (MI) programme tailored to the unique needs of each facility. Key steps included:
- Analysing the existing data for equipment integrity across the sites
- Conducting detailed, targeted inspections for equipment and piping and field verification as necessary
- Developing a unified documentation structure to streamline reporting and management
- Implementing systemisation and circuitisation to optimise inspection processes
To ensure sustainability, our team created MI Guidance policy documents for each site, customised to their specific requirements. This ensured the programme could be efficiently managed and scaled in the future.
Powerful results
The tailored, time-based inspection programme enabled the client to prioritise areas most susceptible to wear, significantly reducing the overall time and resources dedicated to inspections. For example, at one facility, the number of piping circuits was
reduced from 1,500 to fewer than 600 through the correct application of the circuitisation process. This reduction translated to a substantial decrease in inspection efforts, as well as cost savings across planning, field inspections, and data analysis.
50%
At this facility alone, over 50% of piping circuits were eliminated, leading to ongoing reductions in inspection workload and future maintenance efforts.
The client saw notable cost savings and a more efficient inspection process across all sites
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