Customer: Major North Dakota Refinery Operator
Service: Integrity Assurance – Turnaround Support
Industry: Oil & Gas / Downstream
Asset Type
Crude Oil Refinery
Processing Capacity
74,000 bpd
Crude Type
Primarily low-sulfur domestic crude
Flange Sizes
¾" – 60"
Flange Classes
150# to 900#
Flange Classes
150# to 900#
Number of Flanges
10,000 (8,000+ within turnaround scope)
Project Phase
Major Turnaround (4-year cycle)
System Requirement
Full iDMS tracking for all joints
In preparation for a major turnaround involving more than 8,000 bolted joints, a North Dakota refinery operator faced a high-stakes challenge: achieve a 100% leak-free startup across an asset processing 74,000 barrels per day. With costly downtime on the line, multiple contractors on site, and the need to maintain strict HSE and schedule discipline, the operator required a partner with the technical depth, manpower, and proven methodology to deliver integrity assurance at scale. Large scale TAR’s are meticulously planned due to the highly expensive downtime during the regeneration of the entire or parts of the plant. These shutdowns occur every four years due to the need for maintaining, renovating, or refitting of facilities. It is imperative that the plan outage is kept within time constraints - right first time.
Hydratight was selected as the sole integrity assurance provider, based on more than 40 years of expertise managing large and complex turnarounds across the global energy sector.
Gap Analysis & Joint Categorisation
Hydratight provided a gap analysis which was executed by trained and competent Integrity Assurance personnel providing a complete overview of the scope of work and identifying the correct level of inspection and verification for each joint.
Integrity Data Management System (iDMS)
Central to the program was Hydratight’s Integrity Data Management System (iDMS), that was used to track the entire lifecycle of every critical joint. iDMS enabled the team to:
Store the entire lifecycle data relating to every critical bolted joint on an installation It
Provide managers and technicians with essential information about joint components used in assembly.
Specifies the tools and the torque or tension values to deliver a leak-free joint.
Joint Integrity Execution
Despite an evolving scope, challenging weather, and the need to coordinate across multiple contractors, Hydratight deployed trained and competent Integrity Assurance personnel to manage every step of the joint integrity workflow. The Hydratight Joint Integrity team were able to deliver the project on time and leak free.
compliance with site standards, consistent application of procedures, and reliable execution under time pressure.
across all 8,000+ joints
despite adverse weather and shifting scope
through iDMS
ensuring reliable plant performance post-turnaround
through structured workflow and clear joint integrity governance
Hydratight supports operators worldwide with specialist manpower, world-class tooling, and proven integrity assurance programs designed for safe, efficient, and leak-free operations. Speak with our team today to discuss your upcoming turnaround or maintenance campaign.
