Asset Integrity Services
Petromaster’s preferred model, is a total system approach that utilizes an integrated solution for optimum integrity management programs of the various stationary & rotating equipment.
we provide these asset integrity services to our honorable clients:
- Thermography
- Vibration Analysis
- Risk Base Inspection (RBI)
- Off-stream Inspection
- On-Stream Inspection (OSI)
- Boiler Condition Monitoring
- Asset Life Cycle Normalization
- Corrosion Management Programs
- Rotating Equipment Condition Monitoring
However, based on client’s request Petromaster can develop stand-alone Asset Integrity Assurance programs and Predictive Maintenance as well as other maintenance strategy programs.
Our services include engineering and inspection of all service facilities, pressurized equipment, tanks and full turnarounds (T&Is) inspections. In addition, we support grass root facilities during construction and commissioning.By planning capital and operating plant mechanical studies, the condition assessment process becomes an integral part of the overall asset management and planning cycle. Whether it is routine maintenance planning, major maintenance outage planning or planning for a major plant upgrade, it is necessary to have current condition assessment information to support the planning process.
Boiler Condition Assessment
In plants, boilers have typically been the most trouble prone equipment, being the most likely origin of a problem that leads to a forced outage. Because of this, there are well defined techniques to assess the condition and manage the lifecycle of boiler equipment for optimum reliability and efficient operation.
Petromaster provides the highest quality boiler inspection, and condition assessment I services by providing thorough inspections, detailed reports, prioritized repair recommendations, and comprehensive documentation. Petromaster will commit to decreasing your overall outage costs, improve plant efficiency in overall boiler maintenance, increase unit availability and increase “run time” between outages.
Petromaster’s Boiler Condition Assessment program includes:
- Mechanical Integrity Assessment of Boiler Hardware (Drums, Tubes, Burners, Soot blowers, Ancillary Equipment & Structures)
- Boiler Feed Water & Steam Chemical Treatment Programs
- Operational Performance Assessment & efficiency improvements.
We have access to advanced analytical software state of the art technologies, and advanced metallurgical laboratories.Based on detailed Root Cause Analysis (RCA), our recommendations will ensure safe, cost effective and result oriented recommendations in compliance with Industry & Client Engineering Guidelines and local regulatory requirements.
Risk Based Inspection
Petromaster provides Risk-Based Inspection services to refineries, oil & gas processing, petrochemical and power plants. Our RBI programme is designed to both qualitative and quantitative criteria and is based on the American Petroleum Institute RP 580/581 inspection methodologies.
Risk Based Inspection (RBI) is an Optimal business process used to examine pressurized equipment and piping systems in industrial plants. It examines the Health, Safety and Environment (HSE) and business risk of ‘active’ and ‘potential’ Damage Mechanisms (DMs) to assess and rank failure probability and consequence.
This ranking is used to optimize inspection intervals based on site-acceptable risk levels and operating limits, while mitigating risks as appropriate. RBI analysis can be qualitative, quantitative or semi-quantitative in nature.
We at Petromaster, assist our clients to select cost effective and appropriate maintenance and inspection tasks and techniques, to minimize efforts and cost, to shift from a reactive to a proactive maintenance regime, to produce an auditable system, to give an agreed “operating window”, and to implement a risk management tool.
Corrosion Management Programs
Corrosion Management is an integral part of Petromaster’s Asset Integrity Concept. We develop full-fledged corrosion management programs for operating facilities and at design stage. This includes Corrosion Loops, Damage Mechanisms, Inspection Plans, Operation Integrity Windows, Multi-Level KPIs, and a Monitoring scheme at client preference.
Corrosion Consulting:
Petromaster has been providing corrosion consulting, corrosion prevention, and corrosion-control services to various clients.
Our objectives are:
- To provide a high quality service at a reasonable cost
- To develop practical solutions to clients’ corrosion problems to work with our clients as a team.
Investigating failures:
Petromaster’s experienced, professional staff along with its consultants has specialized expertise in corrosion technology and investigating corrosion-related failures. We have investigated many failures due to corrosion and/or mechanical causes. The practical, experience-based backgrounds of our corrosion engineers & our ISO 17025 Accredited Lab Metallurgists qualify us to investigate a full range of corrosion-related failures across different industries.
Vibration Analysis
Vibrations can pose serious hazard to pressurized equipment. It can reduce performance, shorten equipment life, or even cause a catastrophic failure. Plant and equipment vibrations can be hazardous for employees and damaging to your facilities and business collateral. If you are operating on a construction site, vibrations can be extremely dangerous for you as well as nearby businesses and sites. Through our vibrations monitoring services, we can identify the source of any concerns and help you with innovative suggestions to improve the situation.
We conduct continuous monitoring of vibration emissions from construction sites, petrochemicals, power sector, refineries, processing, fertilizers, industrial, rail and transport activities. Through our vibration measurements we can ensure that you are meeting your industry safety guidelines and regulations. We can offer you expert advice on steps to take to improve your operations and avoid failure issues.
Our detailed documentation provides innovative suggestions on ways to reduce vibrations in a plan designed specifically to your needs.
Rotating Equipment Conditioning Monitoring
Misalignment, unbalanced bearings, vibration etc. are the hidden root cause of machine failure. Condition monitoring enable us to check operating condition of machine periodically to prevent these factors causing failure of the machine
Petromaster is providing solution of Integrated Reliability Maintenance services working towards improving plant availability, zero breakdowns and reducing maintenance costs. Petromaster is playing a key role in many process industries by successfully conducting condition monitoring programs and directly contributing to the bottom-line reliability of leading industry.
We have partnered with Industry experts in the field of Asset Management and Maintenance consultancy, Finite Element Analysis, Structural Analysis and CFD analysis to solve the specific Industry problems. We have several successful case studies. Where we could help customers to correct the OEM designs, equipment imperfections, and erection and commissioning imperfections.
We provide consulting services in the area of Asset management consulting and take up short term & long term projects to increase the overall equipment or plant availability, Performance and Reliability.
Thermography Services
Petromaster provides independent specialist thermography services to businesses across Saudi Arabia & the GCC region. Our proven inspection and assessment processes prevent breakdowns, downtime, potential loss of earnings and property loss, and in many cases identify problems not found using traditional inspection techniques. Regular thermography inspections of your electrical assets allow us to identify electrical faults before their failure becomes a costly concern for your business.
Our Thermographers are highly trained technicians with high qualifications and are based in Saudi Arabia to provide support at short notice.
In Infrared Thermography, we use temperature as a parameter to monitor the condition of any machine in operating condition. Petromaster has certified Analysts in its services squad to provide the services of Infrared Thermography to the relevant industry. To take a thermal image there is no need to stop your machine.
We can also use Infrared Thermography to survey your insulated systems to identify hot or cold spots in your insulation, bulges within your boilers water wall tubes, and specialized Infrared Thermography for your furnace tubes.
Asset Lifecycle Normalization
Petromaster’s Propriety Asset Lifecycle Normalization Solution is capable of identifying sections or components within an equipment or process train, recommending the appropriate measures to restore its integrity to a level comparable to the rest of the equipment or train, overseeing its application, monitoring its performance, and overseeing any required repairs or alterations to the system.
On & Off Stream Inspection
Inspection programs whether on-stream or off-stream during planned Turn-Around/ Testing & Inspection (T&I) are an essential variable for an effective Asset Integrity Assurance Program.
Petromaster develops ON-STREAM inspection programs for grass root facilities or improve existing programs for established ones based on client requirements and in compliance with international codes such as API, or Client own Standards. Petromaster can also assist client inspectors & corrosion engineers during T&Is to validate their existing inspection plans and close any identified gaps.
We can also deploy our state of art technologies such as Metal Magnetic Memory (MMM) to optimize their On-Stream Inspection programs to focus more on areas more prone to corrosion at stress-concentration zones on their piping systems and other pressurized equipment.
