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The catalyst
Picture this: A refinery operating smoothly, everything seemingly under control.
Over winter, as the temperatures in Alberta, Canada reach sub-zero, a steam leak goes unnoticed. Ice builds up, and eventually, a 30lb block of ice (the size of a mini fridge) falls off a scaffold.
The ice shears off equipment on its way down and causes $100,000 worth of damage. An operator had walked in the exact location just 30 minutes prior.
Fortunately, no one is injured. But the incident raises questions: “How did this happen? Why wasn’t it caught sooner? How can we prevent it next time?”
This is the real-life incident shared by Marvin Smith, Senior Supervisor of Cenovus Energy, in our recent webinar. It's not an uncommon story.
For decades, maintenance teams have traditionally relied on manual observations, written reports, and physical site visits to understand the condition of large infrastructure.
However, these methods can be time-consuming and extend site shutdown periods, with dependencies on abseiling/rope access, cranes, and heavy machinery.
The solution
A digital-led preventive maintenance program, powered by drone surveys and Trendspek, for greater facility coverage and actionable insights. This has turned potential catastrophic incidents into manageable maintenance tasks, that can be actioned ahead of time.
In our two-part Fireside Webinar Series, we spoke with:
- Cenovus Energy, the third-largest energy and gas operator in Canada
- Osprey Integrity, their UAV testing and inspection partner
Deployment and process
Osprey Integrity deploy advanced drone technology and surveys to capture the entire facility, collecting photogrammetry, NDT and thermal data.
This data is then converted into exact 3D models using Trendspek's platform. Logging in online, specialists can conduct virtual identification of defiencies, analysis and preventive reporting to target and avoid potential risks ahead of time.
Teams can also zoom in on a specific valve, or zoom out to assess an entire row of tanks. With millimetre detail on-screen, they can spot potential risks before they escalate into costly failures.
Courtland Penk, President at Osprey Integrity says:
“To just drop a pin in a 2D map only tells half the story. To make corrective actions, we need to know what it’s like vertically as well. That’s where 3D solutions maximise value. It's not just about data and showing positional information, it's also about trying to alleviate some of the paperwork in the long run."
📈 Key outcomes
450+ defects identified and categorised
Virtual walkthroughs to anticipate access, resources, risk severity
With 24/7 access to 3D models, teams can conduct virtual site walkthroughs to anticipate resources required90% structural coverage
Millimetre detail of asset exteriors, including insulation, leaks, ventilation, thermal, and structural hardware.Interactive repair packages
Shareable 3D models with accurate specs allows for an improved system of engagement.
Marvin Smith, Senior Supervisor at Cenovus Energy says:
“The ability to interact with Trendspek in many different ways is arguably just as important as the quality of the data itself.”
A Service Provider's insights
Technology Enables Cultural Change
“Technology is certainly the enabler to the people, process, and culture changes that have to happen within the business. There’s real value along the way that will just lead to more value with fewer headaches. Early adopters of these technologies are setting themselves up for massive advantages in the next few years.”
Efficiency Through Data Consolidation
“It's not just about data and showing positional information, but it's about trying to alleviate some of the paperwork in the long run. The efficiency and availability of the data then leads to the actionable insight, rather than death by folders.”
“The more that we can consolidate and improve the access and delivery, the viewability, the interaction with that data, the more you're empowering those subject matter experts to provide actionable insights at your facility.
Getting Ahead with Maintenance Needs
"The tools and the way that we can view and provide that kind of information, and also summarise risks and repair process, all in the same environment, you start to tick some boxes."
An Asset Owner's insights
"Find it before it finds you"
“When we talk about preventive maintenance, we're talking about ‘find it, before it finds you’. So that means we're finding the deficiencies first, as opposed to corrective maintenance, where they’re finding us. Anything that's corrective ends up a break-in to schedule, and typically costs 2.5 - 3x more than it would for planned work. We also put people more at risk with unplanned work.”
Compressing the timeframe between data collection and action.
“The goal here, and with the continual advancement in the technology with platforms like Trendspek, is to allow us to continue to compress that time frame between data collection and data action. You can take out all the guesswork with Trendspek’s folder management system. It can be pinged right here, with an XYZ location. It can be marked red, and includes spatial data, so you don't have to read anything to know where it is.”
Minimising turnaround periods using a digital approach
“The turnaround is a really good example. It’s everything from safety to operational — how do we maintain, how do we fix all this without compromising on safety and risk. And when we do shut it down, how do we get the most amount of output done within that time? So it's about how quickly I can make decisions when I've got this set amount of time, set amount of resources.”
Watch the replays
