Refinery Asset Protection Services

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MISTRAS operates as a true asset protection industry leader for downstream refineries, offering comprehensive solutions to reduce downtime, optimize maintenance budgets, and maximize safety.

MISTRAS delivers the full breadth of its value-added, OneSource asset protection portfolio to its customers in the downstream refining industry. Our specialties include:

We’re there to assist you in developing, maintaining, and executing your plant vision. We operate in every part of your plant, enabling us to serve as your asset protection partner. Our value-added OneSource approach means we have the inspection and monitoring solutions to inform you when an asset may fail, the engineering expertise to tell you how that failure may affect plant safety and productivity throughout the rest of your operations, and the maintenance services to repair the damage.

MISTRAS offers asset protection services and expertise for all refinery assets, including:

  • Boilers
  • Cokers
  • Heat Exchangers
  • Piping Systems
  • Pressure Vessels
  • Rotating Equipment
  • Stacks
  • Storage Tanks
  • Terminals
  • Valves

Refinery Inspection Services

MISTRAS is a recognized leader in providing traditional & advanced non-destructive testing (NDT/ANDT) inspection services to ensure refineries continue to operate safely and within regulatory compliance.

We perform inspection services to detect corrosion, cracking, leaking, structural and mechanical fatigue, and a wide range of other flaws in refinery equipment that can impact safe and reliable operations. Using NDT, we perform inspections while our clients’ assets remain in service, enabling them to minimize downtime and maximize productivity.

Our NDT inspection portfolio is expansive, granting us the capability to select the most effective inspection solution for your individual asset or problem, taking into account material of construction, anticipated damage mechanism, location of the asset, safety concerns, and many other factors.

Some of the common NDT inspection techniques we use for refineries include:

API Code Inspection Services

MISTRAS provides inspections to a huge range of regulatory codes around the world. This includes conducting inspections and providing best practice recommendations according to American Petroleum Institute (API) codes.

Some of the most common API inspections and recommended practices that MISTRAS performs are below, though our expansive technician and engineering base allows us to complete inspections to any industry or governmental standard:

  • API 510 Pressure Vessels
  • API 520 Pressure-Relieving Devices
  • API 570 Piping
  • API RP 579 Fitness-For-Service (FFS)
  • API 580 Risk-Based Inspection (RBI)
  • API RP 581 Risk-Based Inspection (RBI) Technology
  • API 620 Design and Construction of Large, Welded, Low-pressure Storage Tanks
  • API 650 Welded Tanks
  • API 653 Storage Tanks
  • API 936 Refractory Lining
Refractory Inspection Services

MISTRAS has extensive hands-on experience in the design, installation, troubleshooting, problem-solving and inspection of all types of refractory lining systems, including applications for:

  • Fluid bed combustors
  • Flexi-cokers
  • Fluid cokers
  • Cat crackers
  • Sulfur recovery units
  • Rotary kilns
  • Furnaces
  • Roasters
  • Autoclaves
  • Boilers

Our refractory experts, certified to API-936 Standards, specialize in refractory system evaluations, detailed design reviews, job scope preparation and refractory product recommendations.

By utilizing stringent quality control procedures while monitoring refractory installation, our clients are ensured a high-quality finished product. In addition to installation oversight, we provide timely material testing for material qualification, in-service testing, infrared surveying, and existing material analysis in accordance with the latest ASTM Standards.

Maintenance & Light Mechanical Services

MISTRAS offers multi-disciplined technicians who won’t just perform inspections, but can also perform maintenance and light mechanical services to repair your assets to return them to service as quickly and safely as possible.

If our technicians find corrosion, defective insulation, or a range of other damages, we’re equipped to perform:

Process Refinery Engineering Consulting Services

MISTRAS’ depth of refinery engineering knowledge is unmatched across the asset protection industry. Our consultants engineering and mechanical integrity (MI) consultation services to optimize facility design and operations. Our expertise helps to support:

  • Operations Management
  • Profit Improvement
  • Plant Equipment Support
  • Project Planning & Execution
Asset Integrity Management Services (AIMS) & Mechanical Integrity Audits

Our consultants help develop and implement custom-tailored asset integrity management services (AIMS) programs, enabling our clients to ensure their assets operate safely and effectively throughout their lifetimes. We also perform mechanical integrity audits of existing programs to identify procedural gaps and improve processes.

Click here to learn more about our AIMS/MI Program services.

Process, Equipment, and Facility Engineering

Our plant equipment consulting services include:

  • Alteration/Repair Scope Determinations
  • Assessment of Non-Coded Vessels
  • Capital Project Services
  • Engineering of Non-Pressurized Assets
  • Failure and Fatigue Analysis
  • Fitness-for-Service (FFS) Assessments
  • Heater Tube Remaining Life Assessment
  • Pressure Equipment Re-Rates
  • Scanning Electron Microscopy (SEM)
  • Surface Replication Assessments
  • XRD Analysis

Click here to learn more about our Process & Equipment Engineering services.

Non-Intrusive Inspection (NII) Plan Integrity Assessments

MISTRAS’ consultants are industry experts in non-intrusive inspections (NII), including NII feasibility assessments, inspection plan development, evaluation, and future recommendations.

Click here to learn more about our NII Special Emphasis Program services.

Process Safety Management (PSM) Compliance

Our PSM programs encompass more than just individual asset or procedure assessments. We offer them as comprehensive, plant-wide initiatives that take into account all assets and procedures that affect process safety. We help you go beyond regulatory process compliance.

MISTRAS’ engineering experts can advise plants on the development of a brand-new PSM program, and/or critique and modify existing programs using NDT technologies and risk based inspection (RBI) methodologies based on each facility's unique needs.

Click here to learn more about our PSM Compliance program services.

Reliability & Maintenance Optimization

Maximizing asset reliability and optimizing maintenance spending goes a long way towards your plant’s bottom line. We offer multiple reliability & maintenance programs that help our clients reduce maintenance costs, reduce downtime by shortening the duration of turnarounds, and extend run length between shutdowns and turnarounds.

Click here to learn more about our Reliability & Maintenance Consulting services.

Risk Based Inspection (RBI) Assessments

MISTRAS’ Risk Based Inspection (RBI) assessment services analyze the potential risks of each asset in your facility in their current operating conditions, and then allows users to choose from highly-effective to least-effective inspection techniques based on the asset’s anticipated damage mechanism.

Click here to learn more about our RBI Assessment services.

Evergreen & Turnaround Asset Protection Teams

In addition to call-out services, MISTRAS serves as asset protection partners for many of our downstream clients by providing full-time, evergreen inspection & maintenance teams.

These teams remain on-site at all times, helping our clients stay aware of any asset damages that may be negatively affecting their facility’s productivity and potentially causing serious safety hazards.

Our evergreen teams offer multi-disciplined technicians that are able to complete inspections, perform mechanical services to repair damages, and access at-height locations through the use of scaffolding or safe, proven rope access techniques.

Many of our clients utilize evergreen inspection teams to support their turnaround planning and execution.

Inspection & Mechanical Integrity Data Management

MISTRAS’ industry-leading Plant Condition Data Management Software (PCMS) is an incredibly powerful tool for refinery operators.

The software stores, organizes, and analyzes all of your inspection and mechanical integrity (MI) data. With PCMS, facility operators have access to previous inspection and maintenance reports, future inspection dates, corrosion data, risk-based inspection (RBI) data, and an expansive selection of other information.

The software is compatible with mobile phones and tablets, enabling technicians to conduct field inspections and immediately input inspection data into pre-populated fields, reducing the risk of manual data entry and providing real-time key performance indicators (KPIs) to management personnel.

The software also offers:

  • Complete Asset Tracking & Analysis
  • Corporate & Site-Level Business Analytics
  • Corrosion Analysis & Trending
  • Embedded RBI Calculators
  • Inspection & Turnaround Planning
  • Reliability-Centered Maintenance (RCM) Programs for Rotating Equipment
  • Safety Relief Valve Management

PCMS is available for a single-site implementation, and it can also be used to centralize inspection data tracking for multiple sites. Many major clients who own and operate multiple refineries throughout the world have implemented PCMS has their global standard at all of their facilities, enabling them to view all of their company’s mechanical integrity data all on one integrated dashboard.

Learn more about MISTRAS' inspection data management solutions here.

MISTRAS Digital: Mobile, Digital Data Reporting

Traditional refinery inspection reporting is an involved process that requires manual data entry, physical transportation of paperwork, and great lengths of time necessary to collect, process, and review data. Seamless transportation of data from the field to the inspection database management system (IDMS) like PCMS® helps to ensure compliance and safety for refinery and process plant assets.

The MISTRAS Digital® field execution platform optimizes the process for requesting non-destructive evaluation (NDE), forecasting schedules, assigning tasks, executing fieldwork, reviewing results, publishing reports, and generating key performance indicators (KPIs). It allows mobile devices to conveniently store and access data and documentation including:

  • Isometric Drawings
  • Weld Maps
  • P&IDs
  • U1s
  • Pipe Schedules
  • Inspection Histories

MISTRAS Digital® automatically inputs data into an IDMS application, making manual reporting a chore of the past, eliminating the need to manually transport files from the field to an office. Being able to receive reports in real-time in an accessible digital format can transform inspection processes with improved uptime and overall efficiencies.

With a virtually paper-free mobile reporting streamlining the reporting process, MISTRAS Digital® is ushering in a new era of refinery inspection data management.  

Learn more about our MISTRAS Digital® reporting platform.

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