Integrity & Inspection
Reliability & Asset Integrity
Senior reliability and asset integrity leadership for complex operating facilities. Capability includes building and optimizing maintenance, reliability and integrity systems, investigating major failures, extending asset life, and converting failure history and condition data into risk based maintenance and integrity decisions.
$500M+ coker fire collateral damage investigation
- UEI
- ZR3PJZEA7A21
- CAGE
- 174X8
- Independence
- Findings challenged before release
- Deployment
- Remote response within 24 hours
What This Discipline Covers
Scope of the technical capability.
Senior reliability and asset integrity leadership for complex operating facilities. Capability includes building and optimizing maintenance, reliability and integrity systems, investigating major failures, extending asset life, and converting failure history and condition data into risk based maintenance and integrity decisions.
- RBI and RBIM
- RCM
- FMEA and FMECA
- RCA and RCFA
- PM and PdM optimization
- Condition monitoring
- Asset criticality and risk ranking
- Maintenance strategy
- Equipment maintenance plans
- Bad actor elimination
- Asset integrity and fitness for service
- Life extension
- Reliability data and KPI systems
- Spares strategy
Problems The Technical Lead Solves
The questions this discipline is engaged to answer.
- 01
Recurring failures
- 02
Major loss investigations
- 03
Reliability program design and audit
- 04
Asset life extension
- 05
Maintenance strategy optimization
- 06
Integrity risk assessment
- 07
Bad actor elimination
- 08
RCA facilitation and corrective action governance
Equipment And Systems
Assets this Technical Lead has worked on directly.
- Pressure vessels
- Piping
- Heat exchangers
- Tanks
- Evaporators and concentrators
- Pumps
- Compressors
- Gas and steam turbines
- Fire water systems
- Process systems
Industries And Environments
Operating environments where this experience was built.
- Oil sands and upgrading
- Oil and gas
- Petrochemical and process
- Pulp and paper
- Power and cogeneration
Diagnostic And Investigation Methods
How the technical work is actually performed.
- Inspection planning and risk based inspection development
- Thickness, corrosion rate, and remaining life calculation
- Damage mechanism identification and screening
- Fitness for service evaluation
- Repair, alteration, and rerating review
- Inspection data management and CMMS integration
Tools Capability
The platforms, instruments and measurement methods used on assignments.
These platforms, instruments and methods are used to produce evidence that holds up under audit, underwriting review and cross examination.
Asset Performance and Integrity Management
GE Vernova APM / Meridium
Asset strategy, reliability analytics and integrity information management across a plant or portfolio.
Cenosco IMS
API 581 risk based inspection calculation of intervals, scope and priority against consequence of failure.
Fitness for Service and Remaining Life
Codeware INSPECT
API 579 assessment, corrosion rate evaluation and remaining life determination from the inspection record.
Enterprise Asset Management
SAP S/4HANA Asset Management
Maintenance strategy, notification and work order history analysis.
IBM Maximo
Work management, asset hierarchy and maintenance record interrogation.
Reliability and Availability Modelling
ReliaSoft Weibull++ and BlockSim
Weibull life data analysis, failure rate estimation and availability modeling used in reliability cases and lender availability review.
RCM, FMEA and FMECA
Maintenance strategy development and failure mode ranking against consequence.
Root Cause and Analytical Method
Apollo Root Cause Analysis and TapRooT
Repeatable RCA and RCFA discipline applied to chronic failures, bad actors and repeat events.
Fault tree and bad actor analysis
Separation of a genuine reliability defect from operating practice, design limit and maintenance execution.
Monitoring, Sensors and Predictive Analytics
AVEVA Predictive Analytics, GE SmartSignal and Aspen Mtell
Model based anomaly detection on historian data to identify degradation before it becomes a loss.
Wireless vibration, temperature and acoustic sensors
Continuous condition coverage on assets outside a route based monitoring programme.
AI camera monitoring
Automated visual watch on plant condition, leaks, access and maintenance activity where continuous human observation is impractical.
Transaction and Lender Evidence
Oracle Primavera P6 and Microsoft Project
Turnaround, shutdown and lifecycle CAPEX schedule review supporting technical due diligence and lender technical review.
Condition and CAPEX modelling in Excel and Power BI
Deferred maintenance, remaining life and capital forecast presented in a form an investment committee can test.
ISO 14224 benchmarking
Comparison of observed failure rates against recognised industry data rather than assertion.
BlackOut Power / TerraTolga Proprietary Capability
- Criticality
Asset criticality ranking that prioritizes inspection, maintenance and capital spend against consequence of failure.
- FMECA Engine
Failure mode, effects and criticality analysis feeding maintenance strategy and inspection planning.
- Engineering Records Intelligence
Structured review of inspection histories, records and specifications behind an integrity or due diligence opinion.
Codes And Standards
Frameworks applied to the analysis.
- API 510, 570, 653 and 580 or 581
- ASME BPVC Sections V and VIII
- ASME PCC-2 repair of pressure equipment
- API 579 fitness for service
- ISO 14224 reliability data collection
- ISO 55000 asset management
- API 580 and API 581 risk based inspection
Credentials And Qualification
The professional basis for this discipline.
- 01
API inspector certifications or equivalent recognized qualification
- 02
NDT qualification and oversight experience
- 03
Mechanical integrity program ownership in operating facilities
- 04
Turnaround and inspection campaign leadership
Scale And Breadth
Reported scale of professional exposure.
- 01
$500M+ coker fire collateral damage investigation
- 02
$200M brownfield business case supported by API 579 fitness for service and 20 year life extension assessment
- 03
87 MW cogeneration gas turbine repetitive outage investigation
- 04
$12M+ revenue loss coker vessel nozzle failure and fire investigation
Representative Professional Experience
Assignment types this discipline supports.
- 01
Development of a risk based inspection program for a pressure equipment population
- 02
Fitness for service assessment supporting continued operation of a degraded vessel
- 03
Investigation of accelerated corrosion and the process change that caused it
- 04
Independent review of inspection records supporting an asset transaction
Assignment descriptions are generalized to protect client confidentiality. Specific references can be discussed during scoping where permissions allow.
Multidisciplinary Interfaces
Disciplines this work commonly coordinates with.
- Mechanical & Failure Analysis
- Inspection & CMMS
- Vibration
- Machinery Engineering
- Process
- Controls
- Electrical
Discuss a reliability & integrity assignment.
Initial conversations are confidential and without obligation. We will confirm independence before scope is discussed.