In this business case, we explore how a major refiner in the Middle East took decisive steps to overhaul its asset integrity practices. Faced with rising maintenance costs, recurring leaks, and the limitations of conventional inspection strategies, the company needed a smarter way to safeguard its critical infrastructure.
Operating from a strategically located facility with a capacity of over 305,000 barrels per day, this refiner serves as a vital hub for producing and exporting fuels and petrochemical products. To stay ahead of operational challenges and protect the long-term performance of its assets, the company turned to Cenosco’s IMS PEI (Pressure Equipment Integrity) module to bring structure, visibility, and efficiency to its maintenance program.
The Need
As the refinery’s operations grew in complexity, its traditional approaches to asset integrity were showing their limits. Maintenance activities were often driven by fixed schedules or reactive interventions, leaving little room for prioritization based on actual asset condition or risk.
Lack of Prioritization and Risk Assessment
Recurring leaks, including Tier‑3 Loss of Primary Containment (LOPC) events, exposed the absence of a risk-based framework. Maintenance activities were not prioritized based on criticality or urgency, leading to inefficiencies and avoidable costs.
Limited Visibility Across Assets
Managing thousands of inspection points across process units, tanks, and utility lines proved overwhelming. Siloed spreadsheets and manual workflows hindered leadership’s ability to see the full picture or plan effectively.
Challenges in Budget Justification
Without structured, data-driven insights, it was difficult to demonstrate the value of preventive maintenance to secure sufficient budgets, especially for integrity-critical activities like coating and corrosion prevention.
To control rising maintenance costs and safeguard critical infrastructure, the refinery needed a smarter, structured approach that aligned inspection efforts with actual risk and provided leadership with actionable insights.
The Solution
To address these challenges, the refinery implemented a comprehensive integrity management strategy built on Cenosco’s Integrity Management System (IMS). This approach enabled the company to streamline its maintenance processes and prioritize critical assets.
Transitioning to Risk-Based Inspection (RBI)
The company moved away from purely time-based and reactive maintenance by adopting Risk-Based Inspection (RBI) methodologies. This shift allowed them to:
- Establishing corrosion loops and assessing damage mechanisms.
- Running comprehensive RBI workshops to enhance staff capabilities.
- Developing specialized strategies for high-risk components such as dead legs, small-bore connections, and dissimilar welds.
By 2016, the company deployed an optimum strategy mix:
- 66% Risk-Based for process piping, equipment, and storage tanks.
- 21% Run-to-Fail for utility lines and condensate systems.
- 13% Time-Based for civil assets and coatings.
Focused Improvement Initiatives
To address key integrity threats, the company launched targeted programs:
- Reducing LOPC Events: A centralized leaks register was created to analyze recurring themes. Continuous monitoring and proactive interventions resulted in a projected 80% reduction in Tier-3 LOPC events over five years.
- Proactive CUI Management: A focused inspection campaign was conducted on over 3,200 critical assets across 200+ locations, preventing 52 potential leaks and avoiding costly production downtime equivalent to two weeks of operations.
Integration and Technology Enablement
The refinery also integrated IMS with its enterprise systems, including a bidirectional SAP interface. This integration eliminated duplicate data entry and streamlined work order execution across inspection and maintenance teams, resulting in additional cost savings. Key innovations included:
- Real-Time Integrity Operating Windows (IOWs) for monitoring critical parameters.
- Deployment of advanced technologies like drones, robotics, and mobile tools, enhancing inspector safety and enabling access to hard-to-reach areas.
The Result
Following the implementation of Cenosco’s IMS platform and targeted integrity programs, the refinery achieved measurable improvements in operational efficiency, cost control, and asset reliability. These results highlight the impact of moving to a data-driven, risk-based approach.
- Higher Maintenance Efficiency: Risk-based planning allowed teams to achieve more work with fewer resources while maintaining rigorous quality standards.
- Fewer Leaks, Safer Operations: Tier‑3 Loss of Primary Containment events fell dramatically, with a projected 80% reduction over five years, and 52 potential leaks prevented through focused CUI inspections.
- Data-Driven Leadership Decisions: Real-time insights now support smarter budgeting and proactive interventions, aligning maintenance priorities with operational risk.
- Cost Savings and Asset Longevity: Timely interventions, such as optimized painting strategies, are projected to reduce replacement costs by up to four times. By preventing unplanned failures and avoiding downtime equivalent to two weeks of production, the refinery is estimated to have safeguarded over $95 million in potential revenue and deferred capital expenditure.
Leading the Way in Middle East Refining
By modernizing its integrity management approach, the refinery has built a foundation for safer, more reliable operations and long-term asset performance. The move to a risk-based strategy brought structure and predictability to maintenance efforts, allowing the company to focus on resources where they matter most.
This shift has also enabled leadership to make confident, data-driven decisions about planning and investment while supporting the refinery’s role as a critical player in the Middle East’s energy landscape. With these improvements in place, the company is now well positioned to meet future challenges and sustain operational excellence for years to come.
Unlocking Value with IMS
The success of this refinery demonstrates how Cenosco’s Integrity Management System (IMS) does more than improve asset integrity. It creates measurable business value. By transforming inspection data into actionable insights and enabling risk-based decision making, IMS empowers organizations to maximize asset performance, reduce operational costs, and enhance safety outcomes.
For refiners and operators across the Middle East and beyond, adopting IMS is not just a technical upgrade. It is a strategic move to safeguard revenues, extend asset life cycles, and achieve operational excellence in an increasingly competitive landscape.
With IMS, your organization can:
- Gain enterprise-wide visibility into asset health through intuitive dashboards and reporting tools
- Optimize maintenance budgets with data driven justification for integrity critical interventions
- Enable your teams with mobile tools, advanced analytics, and integration to enterprise systems for smarter and faster decisions
- Protect production uptime and defer major capital expenditure by preventing costly failures
By choosing IMS, you join a growing number of industry leaders leveraging a proven and future ready solution to secure their operations and strengthen their position in the energy market.
The smartest integrity move you haven’t made yet.
Think $95M in savings is impressive?
Let’s explore what IMS could do for your refinery.
Fill out the form below to get started today.
