Improving Compliance and Reducing Inspection Costs Through Risk-Based Inspection Programs

  • s_Improving-Compliance-and-Reducing-Inspection-Costs-Through-RBI-ProgramsA facility in southern Louisiana needed a plan to achieve regulatory compliance.
  • PinnacleART implemented a comprehensive RBI program at the facility.
  • As a result, the facility has a greater degree of clarity regarding where risks reside in its location.

INTRODUCTION

A petrochemical manufacturing facility in southern Louisiana began production in 1966 and after several additions and expansions, today manufactures Aniline, Toluene Diisocyanate, Methylene Diphenyl Isocyanate (MDI) and Diphenylamine (DPA). These chemical compounds are used in a wide range of products including polyurethane insulation, furniture and bedding, adhesives, coatings and elastomers, footwear and pharmaceuticals.

CORPORATE CHALLENGE

In 2010, this facility needed a plan to achieve regulatory compliance, as well as understand the current condition of its fixed equipment and piping, however, the company was facing an uphill battle. In order to meet its compliance goal within one calendar year, the company would need to invest more than $7 million in inspection costs, which did not include expenses associated with unit shut-down or vessel cleaning and preparation for internal inspections. Even more critical to the team was the need to prioritize and organize this massive inspection endeavor. At that time, the facility was overdue on 90 percent of internal inspections and up to 95 percent of the location’s piping had never been inspected at all. The facility lacked an Inspection Data Management System (IDMS) that could organize its scheduling, activities and location information.