How VEERUM eliminated hundreds of hours of site visits with virtual fit-ups

We know that shutdowns are high-pressure situations where delays can lead to massive financial losses and safety risks. A VEERUM client with a primary extraction facility faced a critical challenge during a planned shutdown. Thanks to VEERUM’s digital twin technology, what could have been a costly delay was prevented, saving the organization both time and money. Here’s how the solution unfolded.

Client challenges

The project involved replacing 13 pumps over three one-week shutdown windows. The facility’s piping, lined with chromium carbide, made it difficult and time-consuming to field fit components. Any engineering or fabrication errors could cause startup delays, escalating shutdown costs and increasing the risk of safety incidents. In a high-stakes environment like this, even a minor tolerance issue could lead to significant problems, putting both the schedule and the team’s safety at risk.

VEERUM’s solution

To address these challenges, VEERUM digitized the existing facility, capturing all spools, pumps, and pipes with laser scanning technology. These scans were compared against design specifications to ensure everything was fabricated correctly. A constructability simulation was performed, virtually assembling components to detect any tolerance issues that could cause installation problems during the shutdown.

By comparing the as-built to the as-modeled environments in a virtual install, VEERUM clients can easily identify misalignments and intolerances in the design, resolving them before they become real-world issues. This approach saved the client hundreds of field hours, prevented rework, and eliminated the risk of delays. During this process, a 30NSP chrome carbide overlay pipe was found to be improperly built, causing a 31mm out-of-square tolerance issue. Left unchecked, this would have compounded into a 130mm misalignment between the final spool and the pump, resulting in costly rework and safety risks during the shutdown.

The results

By identifying the issue early, VEERUM’s solution saved the project from significant delays. The pipe was sent back to the fabrication shop for adjustments at no extra cost to the client. It was then re-digitized and virtually assembled again to ensure the issue was resolved before shutdown began.

• Safety impact: Preventing last-minute rework reduced human stress and unsafe decision-making. Without the digital verification, the team would have faced a major issue on day six of the shutdown, possibly resorting to unsafe practices to complete the pump tie-in. By removing unplanned work, the risk of safety incidents was significantly reduced, and 100-200 hours of field exposure were eliminated.
• Cost savings: Avoiding a 2-3 day delay saved the client an estimated $800,000 to $2.7 million in lost production. This digital verification not only prevented costly rework but also ensured the shutdown schedule stayed on track.

VEERUM’s technology played a crucial role in ensuring the primary extraction facility’s shutdown proceeded without costly delays or safety risks. By comparing as-built to as-modeled environments in a virtual install, VEERUM helped the client quickly identify misalignments and intolerances in design, resolving them before they impacted fieldwork. This proactive approach maintained operational efficiency, kept workers safe, and avoided millions in potential costs. When you have the right data at your fingertips, you can avoid the chaos and make every decision count. Speak to one of our experts to get started today.