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Inspection Report Review

Inspection report review software that lays each contractor reading on the item’s own drawing, so a skipped or copied point shows before it reaches the record.

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Follow one crude overhead report from 07:52 to 08:18 ↓
The problem

A thickness report says complete, and nobody has the week to prove it

After a campaign or an outage, contractor reports land by the hundred as PDFs, spreadsheets and gauge files. The site inspector opens each one beside the plan and the last round in the inspection data system, ticks points, spot-checks values and checks certificates when there is time. Problems go back by email and come back as a new PDF to compare by hand again.

At that volume the check gets shortened to fit. Injection points on a rack, dead legs and bottom heads inside a skirt get skipped while the cover says done. Last round’s values, sent out in the work pack, come back as this round’s. A copied number hides real metal loss, and the skipped spot waits until its clock runs out.

Built forSite inspectorsInspection supervisorsCorrosion engineersInspection contractorsQuality auditors

The Problem Today

Contractor reports arrive by the hundred, and a cover that says complete can hide skipped and copied readings.

8,560
hours a year at an assumed 2 hours for each of 4,280 reports our estimate
5
things the law says each inspection record must name published

Checked by hand today

  • Plan
  • Readings
  • Rates
  • Credentials
  • Skipped where access is hardInjection points and dead legs left for next time
  • Last round copied forwardEqual to the thousandth, so real loss never shows

The Solution

  1. Each reading on the drawingPoints pinned where they were taken, on the isometric, vessel or tank
  2. Planned versus doneThe report against its plan, its own cover and the last two rounds
  3. Paperwork on the dayGauge, step block, technician and inspector checked on the reading days
  4. Pins sent back to redoThe contractor sees which points to redo; a revision is checked again

Built-in controls

  • Supervisor opens the evidence, then countersigns
  • Agents change no reading and set no date
  • Readings load only after two signatures

What You Get

Only checked readings reach the inspection record, each tied to the report line it came from.

  • One queue with clocksEach report accepted, sent back or waiting, by its review clock
  • Clean reports in sampled batchesTwo people open their own random samples first
  • Each value tied to its pageA pin opens the report line it came from
One report, by the minute

07:52 to 08:18: one crude overhead report through inspection report review

A contractor’s thickness report on the crude tower overhead branch and its wash water injection point circuit, received two working days ago. The cover says every planned point was examined.

demoThe refinery, the contractor, the crews and the readings are sample data.

  1. 0107:52

    Six agents read the report before the inspector opens it

    Intake agent and history checker

    Replaying the check shows each agent’s step and how long it took. Intake read 7 pages and matched the work order. The plan matcher pinned 62 points and found 4 not in the report. The history checker found 11 readings repeating the earlier rounds to the thousandth, and put the same technician’s other reports this campaign up for a look. Nothing has been sent.

  2. 0208:00

    A cover claiming 62 of 62 points, over a drawing with 58 taken

    Site inspector

    The report opens as its job: the isometric of the overhead branch, each planned point a pin where it should have been read. Green is taken, hollow amber not taken, solid amber a repeat of the last round. Planned versus done reads 62 planned, 58 in the report, 4 not taken and 11 repeating, with the cover’s own claim set beside the drawing.

  3. 0308:01

    Page 1 of the contractor’s report, with points examined lit

    Site inspector

    One click on the citation opens the contractor’s cover page with the claim highlighted, signed by the contractor’s own inspector the day after the last readings. The page lists the item, the work order and the next inspection the contractor stated. The inspector reads only the line a finding points to, and goes back to the drawing from the side panel.

  4. 0408:02

    Four injection points empty at the wash water quill, with the round due

    Site inspector

    The not-taken filter lights the injection point circuit, and the point three feet downstream opens as a hollow pin. No reading for it is in the report. Its card shows the plan entry, the earlier readings and when it was last read, and the circuit falls due this month. Scaffold for these points was needed at the upper level.

  5. 0508:03

    Eleven drop readings match the last round to the thousandth

    Site inspector

    The repeat filter lights 11 amber pins on the drops to the last two exchangers. One reducer reads 0.322 in this round, exactly what it read last round, while the other 47 points lost a median 0.005 in. The card says nothing on file shows which value is right, so the point needs measuring again. It does not guess.

  6. 0608:04

    11 of 16 checks pass, and two things the agents could not check

    Site inspector

    The checks run down the side. Every planned point taken, the cover against the tables and readings repeating all fail. Gauge calibration, the step block at the start and end of each day, technician certificate, vision exam and inspector certificate all hold on the reading days. Below them sits what could not be checked: whether the scaffold was up, and one reducer with no photo.

  7. 0708:05

    Send back opens up only once each finding has been read

    Site inspector

    With each finding opened from its pin or page, the decision box offers the reason codes, with points not taken and readings repeating already picked, and a note drafted from the findings that the inspector can edit. Accept stays off while a finding is open. The send goes to the supervisor first, and nothing reaches the contractor yet.

  8. 0808:06

    Countersign waits on four pieces of evidence, opened one at a time

    Inspection supervisor

    The plan opens first, with the injection point line lit: four points at the quill and scaffold needed at the upper level. Then the cover, this round’s readings page and last round’s page, each in its own window. The panel counts them, and the countersign button stays disabled until the supervisor has opened all four.

  9. 0908:15

    Sent back on two reason codes, with the answer due in eight days

    Inspection supervisor

    The decision panel now reads sent back to the contractor by the inspector and countersigned by the supervisor, with the two reason codes and the date the answer is due. Beside it, the checks keep their record, 11 of 16 passed. In the audit trail sit the decision, the four opens and the countersignature, each with its time and person.

  10. 1008:18

    The contractor sees 15 points to redo, counted once each

    Contractor lead

    On the contractor’s own view, the same drawing carries the points to redo: four injection points and 11 drops. The two reason codes and the note sit beside them, with the answer date. The lead sees only this firm’s reports, and only once the owner has decided them, and can say the crew will redo the points or disagree with a reason.

Fourteen covers claimed points their own tables did not hold

What the checks found across the 403 reports read so far this campaign. A report can fail more than one.

Planned points not taken

14 reports left out points on the plan, and the same 14 covers said the work was complete.

Readings carried forward

7 reports repeat the last round to the thousandth over three or more points in a row.

Paperwork out of date on the day

21 failed on the near-vision exam and 13 on the technician certificate, and each hold their report.

Rates never worked out

11 reports gave no corrosion rates; the agent calculated them for the corrosion engineer to confirm.

demoSample data, from the working solution.

Around the queue

The rest of inspection report review, from the queue to the load

The same campaign, as the rest of the team sees it. Open any screen to read it full size.

Reports412 reports from the autumn campaign, filtered to the 45 that need an inspector, each with its clock and first finding. None is past the 10-day review clock.
Checks by report typeEach check, what it means and how many of the 403 reports failed it. Piping, vessel and tank reports add their own checks.
CertificatesTechnicians, inspectors and gauges against the days readings were taken. A lapse on a reading day holds the report, here 21 for one technician’s vision exam.
Rates and thin wallsThe corrosion engineer’s queue, thin walls first. A point at or under retirement thickness is held with its repair request, and its due date does not move.
Clean reports130 reports passed every check. Accepting them takes the inspector’s random sample of 8 and the supervisor’s separate sample of 5.
LoadsBatches loaded to the inspection data system after two signatures, with the next due dates each one set and its load file.

demoSample data, from the working solution.

No reading changes and no date moves without a person

The agents read, pin, compare and draft. These calls stay with the inspection team.

A reading is never correctedThe history checker flags a repeat, a wall that grew or a unit typed wrong. Which value is right is for the crew to measure again.
A missing point is never marked takenA hollow pin stays hollow until a reading comes back for it on a revised report.
Thin walls go to the corrosion engineer the same dayWhether the line can stay in service is an engineering judgment under the permit and the site procedure.
Nothing reaches the contractor on one signatureThe inspector decides and the supervisor countersigns after opening the evidence. Only the supervisor settles a contractor’s disagreement.
Dates move only on a signed loadThe rate calculator proposes a next date. It loads after two signatures, and a point at or under retirement thickness sets none.
The agents

Seven agents check the report, and the inspector decides

Each hands to the next, and the last hands to a person.

Intake agent

Opens each PDF, spreadsheet or gauge file, finds its work order and reads every reading with its page.

  • Never edits a reading
  • Returns a file it cannot read
Plan matcher

Lays each reading on the drawing against the plan and the cover’s claim.

  • Never marks a missing point taken
History checker

Compares each reading with the last rounds for repeats, growth, units and digits.

  • Never corrects or deletes a reading
Rate calculator

Works short and long-term rates, remaining life and a proposed next date under the site procedure.

  • Never sets a date
  • Leaves remaining service to the corrosion engineer
Credentials checker

Checks gauge calibration, step block, technician and inspector certificates and the vision exam on the reading days.

  • Never accepts a certificate it cannot open
Review router

Drafts findings and the send-back with pins and reason codes, and routes rates and thin walls.

  • Never sends without the inspector and a countersignature
Load agent

Loads accepted readings to the inspection data system and reports each due date moved.

  • Never loads unsigned data
  • Never overwrites a past reading

Where each report, plan and certificate comes from

Connections are read only, apart from the load after two signatures.

Contractor portal and emailReports as PDFs, spreadsheets and gauge files
Inspection data systemPlans, circuits, past rounds and due dates
Maintenance systemWork orders behind each report
Document managementDrawings, isometrics and the stored reports
Certificate registerTechnician, inspector and gauge certificates

What site inspectors ask about inspection report review

What is inspection report review?

Inspection report review is the owner’s check of a contractor’s inspection report before its readings reach the record. This solution draws each report as its job, with every planned point pinned on the drawing, checks it against the plan, the earlier rounds and the paperwork, and leaves the decision to the site inspector and a countersigning supervisor.

What does it check on a contractor’s thickness report?

Points on the plan that were not taken, and a cover that claims more than the tables hold. Readings repeated from the last round, walls that grew, millimeters typed as inches and rates not calculated. Then the gauge, step block, technician, vision exam and inspector certificate on the days the readings were taken.

How does it catch readings copied from the last round?

The history checker compares each reading with the earlier rounds. A run of readings equal to the thousandth, where the other points on the circuit lost metal, is flagged as a repeat and pinned in amber. It says the point needs measuring again and does not pick a value.

What happens to a reading under retirement thickness?

It goes to the corrosion engineer the same day, with a same-day clock. The point is held with its repair request or assessment, and its due date does not move. Whether the line can stay in service is an engineering judgment made under the permit and the site procedure.

Can the contractor see our internal findings?

The contractor lead sees only that firm’s reports, and only once the owner has decided them. A returned report shows the points to redo, the reason codes and the note. The contractor can agree to redo them or disagree with a reason, which goes to the supervisor to settle.

How are clean reports accepted at campaign volume?

Reports that pass every check wait in one batch. The inspector opens a random sample and the supervisor opens a different one, and both type their names. Any sampled report that is not right stops the whole batch and goes back to findings.

Does it set the next inspection date?

It proposes one, from short and long-term rates, remaining life and the site’s own limit, and shows the sum. The date moves in the inspection data system only when the readings load after two signatures.

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Send us one report
you already accepted.

We’ll lay its readings on your drawing beside your plan and last round, and see what turns up.

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