Case Studies

Engineering Outcomes
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Real projects. Measurable results. Across every sector we serve.

All Oil & Gas Manufacturing Water & Utilities Industrial Pharmaceutical Marine
Offshore stimulation equipment — frac pump operations
01 Oil & Gas / Offshore

Aker BP STMF — Data-Driven Reliability Optimisation

USD 2.5M

Frac pumps were inspected and HP iron pressure-tested after every offshore stimulation — adding 10 hours per zone. Wear and failure data, validated by Monte Carlo simulation, confirmed the wear was non-critical. A defined threshold allowed pumps to run through Zone 3 before inspection, shifting from conservative intervention to controlled run-to-limit. A predictive model now forecasts valve life based on sand type, pressure, rate and fluid viscosity.

  • +5 operational days per 28-day campaign
  • USD 500k saved per day
  • USD 2.5M campaign savings
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Manufacturing production line
02 Manufacturing

Automated Line Redesign

18%

Redesigned and documented a critical production line for a FMCG manufacturer in the East Midlands. OEE improvement sustained across a 12-month baseline period.

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Water treatment facility
03 Water & Utilities

Treatment Works Maintenance Strategy

£420K

Developed and implemented a planned maintenance strategy across 6 water treatment facilities. Annual savings confirmed in year-one audit against baseline costs.

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Hydraulic power unit with pumps and gearbox
04 Industrial / Reliability Retainer

HPU Reliability Retainer — Hydraulic Pump & Gearbox Investigation

Root Cause

Hydraulic pumps and gearbox on an HPU showed accelerated wear flagged by vibration analysis. Weibull life modelling confirmed wear was system-driven, not ageing. A 2018 overhaul had set all pumps to identical pressure settings, creating vibrational resonance. Introducing a pressure differential resolved it. A design deficiency was also identified: no isolation check valves between pumps and the common discharge manifold.

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Pharmaceutical cleanroom
05 Pharmaceutical

Cleanroom Engineering Review

Zero

Full engineering review of GMP cleanroom systems, resolving 23 identified compliance risks. Zero compliance failures recorded across two subsequent regulatory inspections.

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Offshore support vessel
06 Marine

Vessel Maintenance Overhaul

40%

Overhauled the maintenance strategy for a fleet of 8 offshore support vessels. Maintenance cost reduction achieved within 24 months through RCM and spare parts rationalisation.

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