Asset Integrity
An effective asset integrity management program supports improved performance & uptime, reduced lifetime maintenance costs, and diminished risk of operational equipment. For that reason, investing in effective asset integrity programs is a proven strategy to improve overall facility performance, while also ensuring compliance with regulatory requirements (e.g., OSHA PSM and EPA RMP).
Understanding Asset Integrity and Mechanical Integrity
Within this broader risk management framework, Asset Integrity Management (AIM) addresses the full lifecycle of assets. This includes design through operation and eventual decommissioning. Mechanical Integrity (MI) represents a critical subset focused specifically on the fitness-for-service of physical equipment such as vessels, piping, and tanks. MI programs emphasize proper design, operation, inspection, and maintenance to prevent equipment failure and are often driven by regulatory requirements, including OSHA’s Process Safety Management (PSM) standard.
Supporting Modern Asset Integrity Programs
AcuTech provides asset integrity services, working with organizations to develop new, or enhance and modernize existing asset and mechanical integrity programs. Leveraging decades of experience in process safety and risk management in a diverse portfolio of industries, our consultants apply best practices and knowledge to support company needs.
End-to-End Asset Integrity Program Implementation
Our comprehensive approach to program development includes setting a strategy and implementation plan for a new program, creating policies, procedures, and instructions to define the various needs of an asset integrity program, and implementing the program. The program will cover activities such as gap assessments of existing equipment, creating instrumentation inventories and cause and effect diagrams, pipe circuitization, damage mechanism reviews, and asset integrity program training.
When needed, AcuTech will touch on all aspects of asset integrity planning but is also flexible to meet specific enterprise needs. All organizations that partner with AcuTech benefit from AcuTech’s deep knowledge of industrial standards, codes, process safety regulations, and cross-industry best practices. AcuTech’s seasoned consultants possess a wealth of experience in crafting AI/MI programs and procedures, complemented by comprehensive training for on-site personnel.
We help clients make better integrity decisions by connecting technical risk, inspection strategy, regulatory expectations, and data-driven program improvement. Contact AcuTech for asset integrity services today to embark on a journey towards a safer, more reliable, and cost-efficient operational future.
The presentation explores how integrated asset integrity data analysis can improve decision-making and enhance operational safety.
This article explores an important but often overlooked aspect of Process Safety Management (PSM)—the distinction between “should” and “shall” as applied in the OSHA PSM Standard, the EPA RMP Rule and other industry standards.
Integrity Program Development & Optimization
Build stronger programs. Eliminate non-value-added activity. Improve assurance.
- Mechanical & Asset Integrity Management Program Development & Improvement
- Fixed Equipment RAGAGEP & Technical Gap Assessments
- Integrity Management Program Effectiveness Reviews
- Corrosion Management Program Reviews
- Damage Mechanism Reviews & Updates
- Corrosion Under Insulation Program Assessment & Optimization
- Small-Bore Piping Vibration Management Program Improvement
- Safety-Critical Equipment & Integrity Safeguard ITPM Verification
- Data, Workflow, & Work-Process Optimization
- Recommendations to Eliminate Low-Value Inspection or Maintenance Spend
Result: Stronger compliance posture, improved equipment risk awareness, better use of inspection resources, and more defensible integrity decisions.
Risk-Based Fixed Equipment Planning
Focus inspection resources where they matter most.
- Risk-Based Inspection Program Development & Optimization
- Plant Circuitization & Corrosion Loop Development
- Inspection Plan Development
- NDT Method Selection & Optimization
- Pressure Vessel Non-Intrusive / On-Stream Inspection Strategies
- Fixed Equipment Strategy Development
- Generic Equipment Strategy Development
- Robotic Inspection Solution Evaluation & Deployment Support
- Inspection Scope Rationalization Based on Risk & Equipment Criticality
Result: Better inspection prioritization, reduced unnecessary intrusive inspections, improved outage planning, & clearer technical justification for inspection intervals & methods.
Advanced Technologies & Digital Integrity Solutions
Use data and technology to improve visibility, efficiency, and decision-making.
- CML Optimization Using Advanced Analytics
- Inspection Data Management System Evaluation & Selection Support
- Integrity Data Workflow Improvement
- Permanently Installed Wall-Thickness Monitoring Strategy Development
- Technical Guidance for Technology Selection & Implementation
- Project Management Support for Installation & Data Management
- Evaluation of Robotic, Remote, & Advanced NDT Applications
Result: Improved data quality, better trending & decision support, reduced manual effort, and stronger integration between inspection data & integrity planning.
Asset Integrity Execution Support & Assurance
Support implementation, resolve findings, and sustain program performance.
- Mechanical Integrity & Asset Integrity Audits
- Audit Finding Resolution & Corrective Action Support
- NDT Services Technical Guidance
- NDT Contracting Strategy & Scope Development
- Inspection Vendor Oversight Support
- Training & Competency Development
- Technical Procedure Review & Improvement
- Program Implementation Support
Result: Faster finding closure, improved execution quality, better contractor alignment, and more sustainable program performance.
AcuTech’s consultants are well versed in codes and standards developed by industry bodies and will refer to these as well as each client’s local jurisdiction codes and standards. A sampling of the relevant codes and standards can be found below.
- API 510. Pressure Vessel Inspection Code
- API 570. Piping Inspection Code
- API 571. Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
- API 580. Risk-Based Inspection
- API 581. Risk-Based Inspection Technology
- API 650. Welded Tanks for Oil Storage
- API 653. Tank Inspection, Repair, Alteration, and Reconstruction
- API 2000. Venting Atmospheric and Low Pressure Storage Tanks
- ASME B31.3. Process Piping
- ASME B31.4. Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
- ASME B31.8. Gas Transmission and Distribution Piping Systems
- ASME Section VIII. Boiler and Pressure Vessel Code
- ISO 9001. Quality Management Systems – Requirements
- ISO 55000 series. Asset Management Standards (ISO 55000, ISO 55001, ISO 55002)
- NACE SP0102. Inline Inspection of Pipelines
- NACE SP0169. Control of External Corrosion on Underground or Submerged Metallic Piping Systems
- ISA-84.00.01. Functional Safety: Safety Instrumented Systems for the Process Industry Sector
- IEC 61508. Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems
- IEC 61511. Functional Safety – Safety Instrumented Systems for the Process Industry Sector
- API RP 500. Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class 1, Division 1, and Division 2
- API RP 574. Inspection Practices for Piping System Components
- API RP 576. Inspection of Pressure-Relieving Devices
- API RP 580. Risk-Based Inspection
- API RP 581. Risk-Based Inspection Technology
- API RP 584. Integrity Operating Windows
- ISA-62443-3-3. Security for Industrial Automation and Control Systems: System Security Requirements and Security Levels
- BS EN 1090. Execution of Steel Structures and Aluminium Structures
- BS EN ISO 14731. Welding coordination – Tasks and responsibilities
- CCPS Guidelines for Risk Based Process Safety
- STI SP-001. Standard for the Inspection of Aboveground Storage Tanks (Shop-Fabricated)
- FTV RP 2007. In-Service Inspection of Aboveground Atmospheric Fiberglass-Reinforced Plastic Recommended Practice
Our consultants have contributed to the following standards, codes, and programs:
- AcuTech was the lead author for the first CCPS book Guidelines for Asset Integrity Management and provided guidance on subsequent editions.
- AcuTech was the lead author for the CCPS book Guidelines for Auditing Process Safety Management Systems, 2nd Edition, which includes detailed protocols and guidance for assessing asset integrity programs.
- Our consultants has authored numerous white papers through industry conferences and collaboration with industry partners.