Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Extending Asset Life & Improving Equipment Reliability in an Aging Methanol Plant
- Methanol Production
- 25-year-old methanol facility
- Southeast Asia
Obstacles Our Experts Have Transformed into Opportunities
The client—operating an aging methanol facility—was struggling with asset reliability challenges
Unpredictable Failures
Critical equipment like heat exchangers, compressors, and columns were failing unexpectedly
Inconsistent Maintenance Records
Inspection logs were incomplete, and historical failure data was unreliable
Corrosion Issues
Increasing frequency of Corrosion Under Insulation (CUI) and other corrosion-related failures
No Mechanical Integrity Program
The plant lacked a structured approach for monitoring asset health or planning inspections
Aging Assets
Management acknowledged asset aging but lacked a strategy to mitigate its impact on performance and safety
Teec’s Expert-Led Solution: Process Performance Enhancement
Our Team of Experts implemented a comprehensive, data-driven program to improve asset integrity and extend equipment life
What Our Experts Did
Conducted a mechanical integrity audit across the plant, supported by non-destructive testing (NDT)
Applied Risk-Based Inspection (RBI) methodologies to prioritize inspections based on failure likelihood
Developed a corrosion risk map to target high-risk areas for proactive intervention
Built a reliability improvement plan focusing on rotating equipment and failure mode analysis
Created a centralized Asset Health Dashboard to integrate real-time data, maintenance logs, and inspection reports
Teec’s experts didn’t just assess the plant—they provided a strategic plan to safeguard long-term asset health.
Execution Approach by Teec’s Experts
- Conducted visual and ultrasonic inspections of high-risk static equipment
- Analyzed historical failure data and chronic reliability issues
- Performed vibration analysis and thermography on rotating equipment
- Classified all assets using API 580/581 methodologies
- Created custom inspection schedules, techniques, and coverage zones
- Integrated inspection checklists into the Asset Health Dashboard for live updates
- Created a corrosion circuit map to highlight vulnerable areas
- Prioritized short-term (coating, insulation replacement) and long-term (material upgrades) mitigation strategies
- Delivered a 3-year reliability plan aligned with budget cycles
- Trained client teams to use the Asset Health Dashboard for decision-making
- Integrated integrity KPIs into the plant’s monthly reporting cycle
Results & Impact
35% reduction in critical equipment failures within 6 months
95% inspection coverage of identified high-risk assets (up from 40%)
$1.2M saved in avoided maintenance and production losses
28% faster repair turnaround times through proactive interventions
Integrated Value Through Teec’s Data-Driven Solutions
Data-Driven Solutions
Data-Driven Solutions
Teec’s Experts integration of predictive analytics transformed the client’s reactive maintenance culture into a proactive, forecasting-driven mindset.
