Twelve months ago, we took over a flange management program fragmented across three vendors. Inspection, intervention, and reporting were disconnected. The result was predictable — rising leakage events and unreliable data.
The Problem
The client operated over 12,000 critical flange joints across an 840km trunkline. Over time, gasket degradation and bolt relaxation led to increasing leak incidents.
Key issue: No single system of record for flange integrity.
Our Approach
- Single accountable execution team
- Unified data platform for inspection and certification
- Risk-based prioritization (Tier A, B, C)
Execution
The program was executed in parallel phases — inspection, intervention, and reporting — instead of sequential vendor handoffs.
Results After 12 Months
- Zero loss-of-containment events
- 2,800+ joints certified
- $8M+ avoided operational cost
- Full audit traceability
"If your inspection data and intervention records don’t match — your integrity program is already broken."
What Operators Should Take Away
- Ownership matters more than tooling
- Data systems are more valuable than inspections
- Start with highest-risk joints first
