Plant Start-up Integrity Verification
Leak Free Plant Hand-Over
The purpose of a start-up integrity verification program is to deliver a leak free plant on-time and on-budget after any maintenance activity.
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Typical shut down maintenance induced process gas leaks come from;
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Low point drains
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High point vents
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Re-instated flanges
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Barrel Unions
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Instrument connections
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Block valve glands
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Control valve glands
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Actuator seals
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Fin Fan plugs, etc....
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AIS work with our clients to quickly, safely and cost effectively locate maintenance induced process gas leaks and validate them “as repaired” prior to plant hand-over and start-up.
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AIS leak detection and integrity verification surveys form a key part of plant pre-commissioning, start-up and hand-over activities.
Save Time & Cost:
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Save overall labor (cost) and reduce leak detection duration (time) by using only 1 or 2 AIS surveyors with superior leak detection technology to do what would normally take days with a larger crew and traditional methods.
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Save time and cost by complimenting or substituting conventional Nitrogen ”snoop” leak checks.
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Expedite start-ups by quickly finding and fixing very low pressure leaks early in the inspection and test plan (ITP)
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Significantly reduce Nitrogen gas generation and consumption over the staged pressurisation verification and purging sequence.
Continuity:​
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Use the same AISS survey team and technology to also perform post start-up expansion, contraction, vibration and hydrocarbon pressurisation leak checks at operating pressures and temperatures.
​Detect Leaks from:
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Drains,
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Vents,
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Glands,
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Instrument Connections
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Shaft seals, etc...
Flexibility:
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Perform gross leak checks on sub-sections of plant using compressed air well before introducing Nitrogen.
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Roam the plant searching for gross low-pressure leaks early in the Nitrogen purge phase.
Efficiency:
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AIS leak survey technology and methods enable verification of all potential leak sources from multiple angles (including those not on the inspection and test plan punch list)
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Save time by surveying all broken and re-instated flanges and process connections without the need to tape and pin-hole the joint.
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Provide increased integrity by surveying complex potential leak sources like valve glands, instrument manifolds, fittings, shaft seals that can not be taped and pin holed.
Leak Detection Technology
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We use the latest ultrasonic and acoustic monitoring technology to quickly locate and validate even very low-pressure Nitrogen leaks from a long distance away.
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During hydrocarbon introduction we use intrinsically safe Ultrasonic and Flame Ionisation Detection technology to quickly locate, quantify and report hazardous gas leaks.
Experience:
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AIS personnel know where to look for leaks based on their extensive hands-on experience performing process component maintenance and numerous start-up integrity surveys both on-shore and offshore.
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Gas Specific Leak Surveys
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AIS deploy leak detection and quantification technology to target specific gas streams.
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Helium
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Hydrogen
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Nitrogen
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Argon
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Misc Hydrocarbons
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VOC's
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Survey normally closed valves
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Block Valves
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Pressure Safety Relief Valves
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Shut-down Isolation Points
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Minimise Risk:
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Minimise risks by finding and fixing leaks before hand-over.
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Minimise influence of weather on the ability to find leaks (High wind & Rain).
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Reduce risk associated with leak checking complex leak sources that can not be "taped and snooped"​
Safe
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We perform ultrasonic leak detection surveys on “live plant” in major hazard facilities
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We use intrinsically safe monitoring equipment approved for use in potentially explosive atmospheres.
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AIS Airborne and structure borne Ultrasound Monitoring equipment comply with
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Ex II 2G, Ex ib IIB T3 Gb and Ex I M2, Ex ib II Mb, -20Deg C< Ta < +50 Deg C
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Hazardous area leak detection survey services are delivered with zero HSE incidents.
Interactive secure reporting & data management​
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AIS document, communicate and report survey findings via a user-friendly and intuitive 360-degree digital twin of your plant.
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Report against pre-defined inspection and test plan (ITP) sequenced point routes.
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Leak survey data and reports are accessible via the AISS secure web-based reporting interface.
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Leak risk assessment summaries provide an up to date snap shot of overall plant integrity at any stage of the start-up process.
Quality Assurance
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Accurately document the leak free status of all in-scope potential leak sources.
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Survey ALL potential leak sources within your shut down work scope .
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Comprehensive and context rich integrity verification reports.
Engaging
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Effective engagement of operations, maintenance, corporate engineering and contract management personnel on a national and facility specific level.
Cost effective design, implementation and delivery of leak survey monitoring programs across all your production facilities.
Leak survey data outputs compatible with your asset maintenance management and plant operating philosophy.