How bp Lingen uses DIMATE PACS together with its Inspection Data Management System

At bp Lingen refinery, this challenge became increasingly visible, especially in pipe inspection, where large volumes of inspection data are generated every year.

In May 2024 bp Lingen started working with DIMATE PACS alongside its Inspection Data Management System (IDMS). To understand where DIMATE PACS makes a difference in day-to-day integrity work, we spoke with Andreas Schnier, who is responsible for the management and quality of inspection and integrity data at the refinery. Part of his role is the continuous improvement of tools and processes that support integrity-related data handling at bp Lingen.

Andreas Schnier works as an Integrity Data Engineer and is responsible for the structure, quality, and accessibility of data related to Inspection & Integrity at bp Lingen. Andreas has been working for bp for over 20 years and therefore has access to a wealth of knowledge about both internal processes and his area of expertise. Around 700 employees work at the Lingen site. The role of Andreas sits exactly where inspection data, integrity decisions, and compliance meet. He is involved in pipe inspection programs, coordinates closely with bp inspectors, engineering contractors and NDT service providers, and is responsible for data quality and audit readiness. On top of that, he uses inspection results in the refinery’s IDMS to support day-to-day integrity decisions.

What was the main bottleneck before DIMATE PACS was implemented?

The inspection process basically begins with a decision to inspect a specific component or piece of equipment in a defined manner. We do a lot of work around pipe inspection, as this is where the largest amount of documentation is generated. We had an internal project on the paperless inspection process, which attempted to establish uniform standards across the group.

Until recently, the process was as follows:

A decision was made to inspect a specific test point on a pipe, for example an elbow, a tee, or a pipe segment.

1. The inspection was ordered via the company’s ERP system, processes were documented in the IDMS, and the NDT service provider received the order including the required information.
2. The inspection service provider went into the field, carried out the inspection, and then digitized the RT film, for example by preparing JPEG files.
3. A report was created and uploaded as a PDF to the company’s DMS.
4. At the end of the documentation process this report was used by authorities, other specialist departments, and internal documentation.

What changed when DIMATE PACS was introduced?

DIMATE PACS changed a lot in our daily way of working in the department. As part of the paperless process, it is now possible to transfer inspection orders to DIMATE directly from the IDMS. The inspection service provider receives a structured order list and can view RT and UT inspections in the system and start them directly.

Currently, the inspection service provider uploads the RT film directly to DIMATE PACS and evaluates it digitally there. There are three main levels: commissioning, integration with the IDMS, and feedback on measurement results.

The film is evaluated in the system. Afterwards, an engineering contractor reviews this evaluation, compares it with the data in the IDMS, and approves it. Once the review is completed, the measurement results are automatically saved in the correct location within the IDMS.

What benefits do you experience with service providers?

The testing workflows with service providers have become much easier. The reports still have to comply with legal requirements, but handling them is much more efficient. Information is stored centrally in a structured digital environment, changes are traceable, and documentation can be retrieved more easily when needed. It is available when you work with it, not only after time-consuming searches through different documents. The merging, preparation and retrieval of information has become much more efficient. Especially in the case of audits or inquiries from authorities, it is a great advantage to have everything structured in one place.

What impact does DIMATE PACS have on turnarounds and shutdowns?

Currently, our focus is still on pipeline inspection because we have very large amounts of data here. We manage a large number of pipelines with recurring inspection programs. In the long term, the system could also be used for turnarounds. No more paper documentation, shorter distances, and transparency about the current status at all times. You no longer have to run between containers to find out whether an inspection was carried out today or tomorrow.

How does DIMATE PACS support integrity decisions in practice?

The data is clearly assigned to a component and a test point. You are forced to maintain a clean structure, especially for isometrics and intermediate points. We also have a dual control principle for documentation. Measured values are no longer transferred manually but are processed directly in the system. If a measured value is 3.4, this is exactly the value that is entered into the system. This significantly reduces the error rate, which also has a positive effect on internal and external audits. Findings are available more quickly. If the testing service provider detects abnormalities, the bp inspector can immediately access the film, check the details, and make informed decisions. In the long term, the system will reach its full potential when multiple inspection cycles are available and trends can be directly compared.

What changed in collaboration internally and with NDT service providers?

Collaboration has become much more structured. There is uniform naming of equipment, isometrics, and measuring points. Measuring points are defined in greater detail, for example inner and outer bends in pipe sections. The documentation is much more granular and of higher quality. This level of detail was previously available in PDF format but could not be used systematically. Today, it can be evaluated directly from DIMATE PACS and the IDMS.

What works better in the IDMS because of DIMATE PACS?

The data is clear, versioned and in the right place. Documents are uploaded once and remain there. Previously, PDFs passed through several hands, resulting in duplicates and ambiguities. DIMATE is very powerful and scalable, which is essential given the volume of data we handle. In addition, DIMATE PACS enforces a clean data structure, which the IDMS alone does not provide to the same extent.

If you had to summarize the benefits for other refineries in one sentence, what would it be?

It is important to get everyone involved on board and make it clear what role the system plays. DIMATE offers excellent support and is geared towards ensuring that the product is used successfully by the customer. You should start with the core functionality, not try to do too much at once, and take into account that each site has historically grown processes. The goal is to simplify processes, not create new problems.