Success Cases

Case 1 – Client 1: MOPICO Compressors

Year
2024

Domain
Facilities → Compression Systems → Gas Compressors

Focus
Optimization of asset life cycle and alignment with real usage factor

Approach
Adaptive maintenance strategy co-designed with OEM and based on real usage and condition monitoring

Problem
- Symptom: Maintenance strategy based on fixed intervals; very low utilization factor (~2.3%); redundant annual inspections.
- Root cause: Misalignment between OEM-prescribed intervals and actual usage; insufficient application of condition monitoring.

Benefits
- Economic: Cost savings 2025–2034 by reducing inspection frequency.
- OPEX/CAPEX: Optimized logistics, spare parts, and training budgets.
- Reliability: Greater service continuity with lower failure exposure.
- Contractual: More flexibility with suppliers.
- Risk: Contingencies budgeted reduce exposure to unexpected stoppages.

Case 2 – Client 2: Dehydrator EHT X-01

Year
2013

Domain
Equipment Integrity → Pressure Vessels → Dehydrators

Focus
Evaluation of overpressure impact and service requalification

Approach
Consultancy with ASME/API compliance check, NDT, hydrotesting, and risk analysis

Problem
- Symptom: Overpressure incident (~350 psi) created uncertainty on equipment structural integrity.
- Root cause: Exposure above plastic collapse pressure (265 psi) led to material yielding and residual stresses; insufficient corrosion-under-insulation and fluid data.

Benefits
- Economic: Avoided premature replacement of >25-year-old critical dehydrator.
- Safety: Clear safe operating conditions reduced catastrophic failure risk.
- Reliability: Extended life through focused monitoring of critical damage mechanisms.
- Contractual: Documented support for regulatory and contractual continuity.
- Risk: Minimum RLI identified; mitigation through containment, resilience, and insurance.

Case 3 – Client 3: Oil Treater EHT-104 (Flange Integrity)

Year
2014

Domain
Equipment Integrity → Pressure Vessels → Oil Treaters (Connections & Flanges)

Focus
Management of recurrent flange failure through reverse engineering

Approach
3D modeling, static simulations, ISO/NP 14224-based failure cause classification

Problem
- Symptom: Recurrent emulsion leakage at main flange joint between vessel and firetube.
- Root cause: Accumulated improper practices during firetube mounting/dismounting; poor execution of major maintenance; unjustified gasket specification changes.

Benefits
- Economic: Prevents leaks and non-programmed shutdowns; avoided premature replacements.
- Safety: Reduced risk of critical flange failures.
- Reliability: Extended service life and process continuity.
- Contractual: Compliance with ASME and international repair standards.
- Risk: Mitigation of accumulated damage via standardized assembly/maintenance practices.

Case 4 – Client A: CPF Separation Systems

Year
2022

Domain
Facilities → Separation & Treatment → Oil & Water Separation

Focus
Fitness for purpose of separation trains

Approach
“Fitness for purpose” methodology with on-site performance testing

Problem
- Symptom: Uncertainty on real capacity of crude and water treatment systems.
- Root cause: Theoretical design not aligned with real operating conditions.

Benefits
- Economic: CAPEX savings; avoided unnecessary expansions.
- Safety: Mitigated overloading risks.
- Reliability: Traceable data on actual performance under operations.

Case 5 – Client B: Multiphase Separators

Year
2023

Domain
Facilities → Separation & Treatment → Multiphase Separators

Focus
Evaluation of effectiveness of multiphase separators

Approach
Construction of mathematical effectiveness functions calibrated with field data

Problem
- Symptom: Low visibility of separator performance.
- Root cause: Absence of standardized and comparable effectiveness metrics.

Benefits
- Economic: Investments prioritized based on real performance.
- Probability of Success: Evidence-based decision making.
- Reliability: Uniform technical criteria for benchmarking.

Case 6 – Client F: Water Quality (Soft Water Systems)

Year
2022

Domain
Laboratory & Data Assurance → Water Quality & Chemistry

Focus
Verification and validation of soft water quality data

Approach
Metrological assurance and standardized laboratory protocols

Problem
- Symptom: Lack of trust in lab results on water quality.
- Root cause: Non-traceable and non-validated protocols.

Benefits
- Reliability: Consistent, auditable data.
- Safety: Reduced risk of equipment failure from poor-quality water.
- Governance: Stronger audit support and decision confidence.

Case 7 – Transportadora de Gas: 8” Gas Pipeline MAOP Review

Year
2024

Domain
Pipeline & Transportation → Transmission Pipelines (Gas)

Focus
Technical derating of Maximum Allowable Operating Pressure (MAOP)

Approach
Design review, inspections and risk modeling under ASME B31.8 / API 1160

Problem
- Symptom: Uncertainty over safe MAOP and long-term reliability of 8” transmission line.
- Root cause: Degraded original design conditions; need to align MAOP with integrity and regulatory limits.

Benefits
- Economic: Avoided premature line replacement.
- Safety: Operating safely within regulatory limits reduced catastrophic failure risk.
- Reliability: Extended service life with adapted monitoring.
- Contractual: Strong alignment with regulatory standards.
- Risk: Exposure to major incidents reduced with controlled derating.

Case 8 – CPF Operator: Validation of Water Lab Protocols

Year
2023

Domain
Laboratory & Data Assurance → Metrology & Data Validation

Focus
Validation and metrological assurance of water lab protocols

Approach
ISO-compliant validation methodology with metrology practices in labs

Problem
- Symptom: Inconsistencies and lack of traceability in water lab results.
- Root cause: Non-standardized protocols lacking metrological validation.

Benefits
- Reliability: Comparable, auditable datasets.
- Safety: Lower risk of equipment damage due to wrong lab results.
- Governance: Stronger evidence in audits and technical decisions.

Resumen

Año Domain Focus Approach Problema (Síntoma + Causa Raíz) Beneficios (resumen)
2024 Facilities → Compression Systems → Gas Compressors Optimización del ciclo de vida, alineación con uso real Estrategia adaptativa consensuada con fabricante y datos reales Estrategia fija vs uso real; inspecciones redundantes. Desalineación planes del OEM y monitoreo por condición. Ahorros significativos; OPEX/CAPEX optimizado; mayor continuidad; riesgo controlado.
2013 Equipment Integrity → Pressure Vessels → Dehydrators Evaluar impacto por sobrepresión y aptitud de servicio Evaluación documental, END, hydrotest y análisis API-571 Incidente de sobrepresión (~350 psi), incertidumbre de integridad estructural. Plastificación + tensiones residuales. Evita reemplazo; operación segura; extensión vida útil; soporte contractual.
2014 Equipment Integrity → Pressure Vessels → Oil Treaters (Connections & Flanges) Gestión de falla recurrente en bridas con ingeniería inversa Modelación 3D, simulaciones y clasificación ISO 14224 Fugas recurrentes de emulsión; malas prácticas en montaje; cambios en empaques. Evita fugas y paradas; seguridad uniones críticas; vida útil extendida; cumplimiento normativo.
2022 Facilities → Separation & Treatment → Oil & Water Separation Evaluación de aptitud de sistemas de separación Metodología de aptitud con ensayos en operación Incertidumbre capacidad real. Diseño teórico no ajustado a condiciones reales. CAPEX evitado; mitigación de sobrecarga; trazabilidad en desempeño.
2023 Facilities → Separation & Treatment → Multiphase Separators Evaluación de efectividad de separadores Funciones matemáticas calibradas Baja visibilidad de desempeño; ausencia de métricas comparables estandarizadas. Inversión priorizada; decisiones basadas en evidencia; criterios comparables.
2022 Laboratory & Data Assurance → Water Quality & Chemistry Verificación/validación de datos de agua Aseguramiento metrológico y estandarización protocolos Falta de confianza en datos; protocolos de lab no trazables ni validados. Datos auditables; menor riesgo en equipos sensibles; soporte a auditorías.
2024 Pipeline & Transportation → Transmission Pipelines (Gas) Derrateo técnico de MAOP Análisis de diseño, inspecciones y riesgos bajo ASME B31.8 / API 1160 Incertidumbre sobre MAOP; degradación condiciones diseño; necesidad de ajuste normativo. Reemplazo evitado; operación segura normativamente; vida útil extendida; gestión contractual sólida.
2023 Laboratory & Data Assurance → Metrology & Data Validation Validación y aseguramiento metrológico de datos de agua Metodología ISO e integración de prácticas metrológicas Inconsistencias y falta de trazabilidad en resultados de laboratorio; protocolos no estandarizados ni validados. Datos consistentes y auditables; menor riesgo; robustez en auditorías.