Nexus Streamlines Inspection Planning for Successful Refinery Turnaround
Overview:
Facing an upcoming turnaround on a compressed timeline, a major Midwest refinery partnered with The Nexus Team to strengthen their inspection planning efforts. With critical mechanical integrity requirements approaching and limited time to prepare, the client needed a reliable solution to support turnaround readiness and ensure compliance.
Nexus deployed experienced specialist Duane Carlson to serve as interim Inspection Manager and lead the development of a focused, conformance ready inspection strategy. Through close collaboration and a tailored approach, the team was able to identify key risks, build effective inspection test plans, and position the site for a successful turnaround, all within a six-month window.
Challenge:
A major Midwest refinery faced an upcoming turnaround with just six months to meet Level 3 mechanical integrity requirements. However, with the expedited schedule, it lacked adequate inspection staffing, foundational test plans, and reliable equipment data, to complete the reviews on time.
Traditionally, a comprehensive Risk-Based Inspection (RBI) and Damage Mechanism Review (DMR) process would take up to two years to complete. Further complicating the effort, incomplete historical records and unclear risk profiles left the refinery vulnerable to costly delays and compliance issues during the turnaround.
This made it challenging to evaluate equipment conditions or establish credible risk profiles. Without a clear understanding of what equipment was nearing the end of its lifecycle, the site faced significant exposure, potentially uncovering major issues during the turnaround itself. This uncertainty threatened to derail schedules, strain budgets, and introduce unnecessary risk to operations.
Solution:
The refinery brought in Nexus and industry specialist Duane Carlson as interim Inspection Manager. Duane led the development of a “DMR Light” strategy – an accelerated, fit-for-purpose approach tailored to the site’s unique challenges.
Key challenges included:
- Reviewing every piece of equipment on site
- Leveraging existing site data (e.g., PI ProcessBook dashboards, archived P&IDs, process files)
- Identifying credible damage mechanisms
- Developing prioritized inspection test plans
- Compiling a critical equipment list
This agile method delivered risk-informed recommendations without the time burden of a full-scale RBI/DMR process.
By completing the effort in under six months, Nexus positioned the client to enter their turnaround fully prepared. The refinery was able to avoid costly surprises and delays, supported by a clearer understanding of aging assets and a focused inspection roadmap.
With early identification of vulnerable equipment and risk-prioritized plans in place, the team improved budget accuracy, aligned procurement efforts, and upheld regulatory compliance. This approach not only minimized operational risk but also reinforced the client’s confidence in their turnaround strategy and overall mechanical integrity program.
