The Documented Experiences of AOC

Some of your challenges include safety and risk, compliance with regulations, aging assets, inefficient processes, meaningful KPIs, human Factors, the need to reduce costs, and loss of knowledge due to a retiring workforce. The following case studies explore how, together with others in your industries, we have achieved sustainable solutions to these challenges.

The MI Assessment - Understanding Your Mechanical Integrity Goals

The MI Assessment - Understanding Your Mechanical Integrity Goals

Compliance? | Best Practice? | Risk Reduction? | One Step at a Time? | Capture Personnel Knowledge? | All Of The Above?

We will take you through a systematic, step by step process leading up to completing a world class RBI program at a major fertilizer manufacturer.


Operational Readiness - Ensuring the Transition from Construction to Startup to Operations and Maintenance

Operational Readiness - Ensuring the Transition from Construction to Startup to Operations and Maintenance

Design basis RBI? Why not optimize all your asset families prior to RFSU?

A major LNG Owner Operator has multiple projects at the EPC phase in addition to an existing facility. From the OWNER'S perspective, a key point of frustration involves migrating "all that asset data" as early as possible into a CMMS and AIM that is comprehensively aligned with asset taxonomy of the ERP.


Data Mining, Management, and Migration

Data Mining, Management, and Migration

Sometimes moving millions of data fields from ten different databases to another seems like trying to get a thousand birds to leave the branches of one tree and land on just the right branches of another.

Sometimes moving millions of data fields from ten different databases to another seems like trying to get a thousand birds to leave the branches of one tree and land on just the right branches of another.


Production Loss Accounting - Heat Exchanger Bad Actor Analysis

Production Loss Accounting - Heat Exchanger Bad Actor Analysis

Heat exchanger failures contribute to over $146M in losses for a large refining enterprise.

A bad actor analysis is a key component of any maintenance and reliability study. As in the case of this refining enterprise, we were able to save the owner over $100M in lost opportunity expenses with a simple solution.


Risk Based Inspection: What To Expect

Risk Based Inspection: What To Expect

Significant findings, even after ten years.

Do you know how to prepare for implementing an RBI program? Here is a perspective from an owner who has been managing an RBI best practice for close to 10 years.


Meaningful KPIs

Meaningful KPIs

Anything worth doing is worth doing right.

How do you measure success, both personally and professionally? What are the goals we set for ourselves, at home and at work? What are the behaviors we want to encourage? What are the behaviors we want to discourage?

The following case studies reveal how these companies set goals that were both personally as well as professionally encouraging. In each of these case studies, these companies developed an environment for continually improving and measuring the performance of their asset management program as well as the performance of their people, all with safety as the overarching goal.The process however, was not as simple as delineating KPIs as part of a set of project requirements.


OSHA Compliance

OSHA Compliance

What do you do when you are on the job for six weeks and you have a toxic leak twice the release of the recent DuPont event? Not to mention the fact that it is only 1992 and OSHA 1910.119 is just getting started...

In 1992, our Vice President of Technology faced an uncontrolled leak of 50,000 pounds of Methyl Mercaptan. He had been on the job as a brand new maintenance engineer for only six weeks when the event happened. To make matters worse, OSHA and EPA representatives and the media showed up at his site soon afterwards. The resulting audit of his site required him to gather over 175,000 documents, and for the next six weeks, he spent his time giving depositions. The regulator had established that his company had no MI or PSM program.


Storage Tank RBI

Storage Tank RBI

How many RBI studies have been completed on above ground storage tanks (ASTs)? We have completed hundreds.

The process industry is faced with increasing economic pressure and a no-tolerance attitude toward environmental accidents. The presence of a large number of storage tanks containing dangerous products constitutes one of the major risks of pollution. Storage tanks are continuously subjected to environmental effects, unavoidably leading to degradation under the form of a corrosion attack. This degradation causes a gradual loss of material and accumulates over the years, ultimately resulting in complete wall penetration and leak formation. Through a leak, the contained product will pollute soil and groundwater. RBI is well established and widely used in the oil and gas, refining, petrochemical and chemical industries. Internal examination of storage tanks, especially of the floor, is difficult and costly. Prioritizing inspections and repair based on risk can improve reliability by focusing inspection resources on those damage mechanisms driving the tank's risk.