Mechanical integrity, API inspection, and commissioning during a major shutdown in the oil & gas industry in Colombia

During the turnaround window, considered one of the most complex and high-risk phases in the lifecycle of an industrial facility, Applus+ teams carried out inspections of static equipment, modernized industrial systems, integrated new gas compression systems, and performed functional validation of electrical, mechanical, and control infrastructure.

The project scope included certified internal inspections of 45 static assets in accordance with the API 510 standard, including pressure vessels, flow lines, and other critical process equipment. These activities identified corrosion-related degradation mechanisms, enabled the necessary repairs, and updated the technical information used in Risk-Based Inspection (RBI) methodologies, strengthening the planning of future inspection and maintenance campaigns.

In parallel, Applus+ supported quality assurance and commissioning activities for a strategic gas compression integration project designed to process gas from low-energy wells. During the turnaround, the company completed the electrical, mechanical, and control tie-ins required to ensure the successful integration of the new equipment and prepare the infrastructure for its future commissioning.

The project also included the complete modernization of the industrial communications infrastructure through the migration from a ControlNet network to a more robust, secure, and reliable Ethernet architecture. As part of this work, Applus+ carried out more than 650 commissioning tests, communication validation activities, functional tests, and system verification procedures, ensuring a seamless technology transition without affecting plant start-up operations.

In hydrocarbon facilities, a major turnaround represents one of the periods of highest operational risk, as any deviation during inspection, maintenance, or start-up activities can compromise personnel safety, asset integrity, operational continuity, and the plant's financial performance.

For the plant operator, risks such as loss of containment, pressure vessel failures, uncontrolled energy release, industrial communication failures, or start-up issues must be managed through integrated inspection strategies, mechanical integrity assessments, and a structured commissioning program.

Applus+ mitigated these risks through a comprehensive approach based on certified inspection, mechanical integrity assessment, functional validation, and continuous technical oversight, ensuring full traceability, compliance with international standards, and operational control throughout every stage of project execution.

The project was carried out under strict Health, Safety, and Environment (HSE) controls, including hazardous atmosphere management in environments containing H₂S and CO₂, working at height procedures, hazardous energy isolation, continuous gas monitoring, controlled site access, certified personnel, and dedicated emergency response protocols.

As a result, 100% of the scheduled turnaround activities were completed, the mechanical integrity of all inspected equipment was restored, and the new industrial communications infrastructure was delivered fully operational, with no disruptions during plant start-up and stabilization.

In addition, the future integration of the new gas compression systems will increase gas handling capacity and help extend the productive life of existing low-energy wells, improving the facility's overall efficiency and reliability.

Through this project, Applus+ further strengthens its position as a strategic partner in mechanical integrity, API inspection, industrial commissioning, technology modernization, and operational reliability for the oil and gas industry, providing the technical expertise required to transform critical turnaround windows into controlled, safe, and reliable operations.