SHUTDOWN & TURNAROUND PACKAGE (V-TAR)
In the oil & gas, power generation and mining industries, turnarounds (TAR’s) are a critical time in the ongoing operation of a facility. These peak and intense activity periods make it imperative to have the correct planning, the right equipment, and most importantly, the best people. A well-planned shutdown can positively impact the plant, have it running at capacity, and significantly extend the facility’s operating life. Vertech believes we are industry leaders in achieving these outcomes.
SD & TAR inspection, upgrade or repair projects can often be a critical step to production recommencing, so delays can cost asset owners millions in lost revenue. Over the last decade, Vertech has refined our pre-planning, pre-mobilisation and work scope assessment processes to ensure every small detail is accounted for and the chance of delay is as small as possible. By ensuring logistics are well organised, our teams arrive on-site armed with everything necessary to deliver the job effectively.
Vertech has completed major shutdown and turnaround projects across Australia and New Zealand, providing world-class services, including.
Shutdown & Turnaround Planning
Successful shutdown (SD) or turnaround (TAR) projects require thorough planning and early engagement with the inspection teams, the client’s teams, and other technical specialists needed for the planned activities. Establishing preliminary communication channels ensures a comprehensive and shared understanding of the specifics of the shutdown, such as the prioritised tasks and critical path items.
Regardless of the asset's condition, our plant inspection and integrity management experience is invaluable to the planning phase, removing assumptions while also reducing the risk of on-site variables.
Vertech's V-TAR Package has been refined over many major and minor, planned and unplanned projects across Australia and New Zealand. Our V-TAR project planning capabilities include a comprehensive array of project management services to complement the operator's personnel to ensure safe, efficient, and high-quality implementation. Our pre-planning and planning capabilities include:
- Work Pack Generation
- Integrated Activity Planning
- Rescue Planning
- Rigging & Lift Planning
- Procurement and Logistics
- Competency Management
- Pre-job Mock-up Trials & Training
Turnaround Inspection Services
The Vertech V-TAR Shutdown and Turnaround Package provides our customers with a comprehensive range of high-value high-quality people and inspection technologies to add maximum value to inspections. Key service lines we have invested in include;
Storage Tank Inspection (MFL & API 653)
Vertech’s Tank Testing Division specialises in the inspection and testing of above-ground storage tanks. Shutdowns and turnarounds can be the ideal opportunity to complete these inspections, and as such, we have the latest generation of Magnetic-Flux Leakage (MFL) floor tank scanners and multi-disciplined API 653 inspectors to conduct the statutory inspections. Vertech’s weld and materials engineers provide support to this division to enable quick solutions, resulting in a significant value add during these critical activities.
AICIP Pressure Equipment Inspection
Vertech has been carrying out intrusive inspections on pressure equipment for asset shutdowns and turnarounds across Australia and NZ since its inception. Our inspectors are well trained, highly competent and hold complementary qualifications in Non-Destructive Testing (NDT), Confined Space Entry (CSE) and IRATA rope access to provide maximum flexibility and value during dynamic shutdown requirements.
Unmanned Aerial Vehicles (UAV) Inspection
Vertech is fully accredited with the Civil Aviation Safety Authority (CASA) and numerous Marine Class accrediting bodies (BV, LR and ABS) to deploy UAV's to inspect confined spaces such as pressure vessels and marine tanks. We have a fleet of drones, which when combined with Vertech’s AICIP/ inspectors or Marine Class inspectors can complete high quality and efficient statutory inspections that remove working at height and rope access.
Remote Digital Visual Inspection (RDVI)
Vertech has heavily invested in the latest generation of Remote Digital Visual Inspection (RDVI) cameras and robotic crawler platforms. We’ve proven across large- and small-scale shutdowns, we can significantly reduce confined space entry (CSE), improve data quality and still meet or exceed all statutory inspection requirements. We have one of the largest teams of skilled, dedicated RDVI technicians in the APAC region, armed with an extensive fleet of the latest generation cameras and crawler systems.
Rope Access NDT Inspection
Vertech is certified to ISO 17205 as an NDT inspection body and can provide our clients with one of the largest teams of IRATA Rope access and ground-based Non-Destructive Testing (NDT) technicians in the country. Our NDT teams are multi-disciplined, being able to perform UT, MPI, DPI, ECI and Radiography while also holding value add qualifications such as CASA, NACE, LEEA lifting, CSE, STOPAQ, first aid and long line BA.
STRUCTURAL & COATINGS
Vertech provides a comprehensive array of in-service inspection, NACE, NDT and rope access personnel to complete inspection’s and high mobility remediation on structures not accessible during production. This is often required for loading jetties, flare tips, flare structures and cryogenic lines (can reach -180 °C while in operation). Due to such low temperatures, cryogenic pipes face unique corrosion and deterioration challenges.
Turnaround Advanced NDT Inspection
Sonomatic has a proud reputation for providing cutting-edge advanced inspection services to support the safety and integrity requirements of shutdowns and turnarounds across the globe. In Australia, the Sonomatic team forms the advanced inspection arm of Vertech Group, which means our clients benefit from both companies’ specialist skill sets and services under one cohesive shutdown team.
Sonomatic focuses on executing as much advanced NDT prior to a shutdown as possible; having developed techniques and guidelines for online inspection of pressure vessels, and piping. Due to temperature, insulation, access or other requirements, sometimes advanced inspection must be done during the shutdown. For this, Sonomatic has a dedicated team lead by subject matter experts that can support planning, execution and shutdown decisions for TOFD, Phased Array, Corrosion Mapping or other specialist techniques.
Sonomatic have a dedicated tube inspection team lead by experts that can support planning, execution and shutdown decision making. Technology is quickly evolving in the tube inspection space and expertise is needed to ensure the most efficient use of equipment and inspection techniques are utilized. We have one of the largest teams of skilled, dedicated tube inspectors in the APAC region, armed with an extensive fleet of the latest generation equipment and techniques.
Turnaround – Emergency Response & CSE Management
Vertech has provided high-mobility, experienced teams to support and deliver a complete emergency response and confined space entry (CSE) management service for shutdowns and turnarounds across Australia. Our people hold qualifications such as IRATA rope access, confined space entry (CSE), gas test atmosphere, long line breathing apparatus (BA) and advanced first aid certification, leaving our client’s site implementation teams to deliver their shutdown activities with the confidence that they have the best in the industry available to respond in any situation.Confined Space Rescue & Management
Confined spaces can be deadly without the proper training, processes, procedures and emergency response provisions. Vertech has delivered high-risk projects within confined spaces such as marine tanks, storage tanks, pressure vessels and storage bins for over a decade. Industrial rope access techniques combined with the correct planning, supervision, training, and equipment are critical to ensure the safe management of CSE and effective rescues in emergency situations.At Height Rescue and Recovery
Vertech has been delivering complex projects from its inception, providing IRATA Industrial rope access services and rescue services on thousands of projects across numerous market sectors. Industrial rope access techniques are one of the most efficient means of conducting rescues at height with unparalleled speed and efficiency. As an IRATA rope access operator and trainer with one of Australia’s largest purpose-built training facilities, we can select, upskill, and refresh people on an ongoing basis.Rescue Equipment Supply
Shutdowns and turnarounds require a lot of front-end planning and engagement across the supply chain. Vertech’s rescue, management, procurement, and logistics teams take on the burden of providing a comprehensive suite of emergency response, working at height and confined space entry equipment. Vertech ensures effective and efficient rescues using this approach, while the client saves on capital costs and complex reviews and certifications.
- Rescue Stretchers.
- Tripod Rescue Systems.
- Rope Access Rescue Systems.
- Breathing Apparatus.
- First Aid Equipment.
- Barriers and Signage
- Lighting Systems
- Radio Systems
- Personal Gas Monitors
ILNG, CPF & FPSO SHUTDOWNS
Vertech provided approximately 130 multi-skilled inspectors, tradesmen, and rope access personnel to provide shutdown work simultaneously across three assets. The scopes included rope access emergency response, a flare tip replacement, 15 RDVI teams, NDT inspectors, a mechanical team, and AICIP in-service inspectors for various inspections. The turnaround was a great success with all key deliverables met.
In 2021, Vertech delivered the inspection services for Santos’ Gladstone LNG plant turnaround. The scope included inspection engineers, advanced NDT, rope access, in-service inspection of pressure equipment and Remote Digital Visual Inspection (RDVI) teams. The turnaround was delivered safely and to a very high standard by all parties, with exceptional client feedback on the execution.
Vertech delivered a 28-day scope of works during the 2021 GWA turnaround, providing a highly skilled and multi-disciplined team to complete the complex task of replacing the exhaust stack and remediating the flare tower’s structure. The team was comprised of IRATA rope access, mechanical, rigging, inspection, electrical, coatings and scaffolding personnel. The site-based leadership was the real success factor for the effective and safe delivery of this shutdown.
OKHA, NGA, NY & NE SHUTDOWNS
Between 2014 and 2020, Vertech was engaged to complete all shutdown and turnaround inspections across Woodside’s fleet of floating assets. Scopes of work included IRATA specialist trade and maintenance services, RDVI, AICIP intrusive pressure vessels inspections, safety-critical inspections, Non-Destructive Testing (NDT), and coating remediation across all areas of the topsides. Outages were often opportune times to complete flare structure inspections and composite applications to crude oil tanks.
Sonomatic were engaged to provide a significant High-Temperature Hydrogen Attack (HTHA) inspection in a 72-hour inspection window. Sonomatic provided 14 advanced inspection teams and 4 Level 3 Advanced NDT experts. by having work fronts across multiple areas of the facility, Sonomatic were able to confirm vessels could safely be put back in service in the 72-hour window.
Sonomatic were engaged to provide Advanced NDT, tube inspection and integrity engineering services during the Karratha Gas Plant shutdown. In total, Sonomatic provided 12 tube inspectors, 4 Senior Tube analysts, 4 Advanced NDT inspectors and 2 integrity engineers. Sonomatic were able to provide quick inspection results and integrity recommendations leading to a successful turnaround.