CAD Services including Inspection Drawings/ISO’s

CAD Services are integral to maintaining mechanical integrity, providing detailed and precise inspection drawings and ISO’s (Isometric Drawings) that are crucial for accurate assessment and maintenance planning. Our skilled team utilizes cutting-edge CAD technology – our in-house plugin is coined “Blue Hawk® CAD” – to create comprehensive visualizations of your mechanical systems, enabling precise inspections and reliable documentation. These detailed drawings facilitate clear communication, precise measurement, and thorough analysis. By integrating our CAD services into your mechanical integrity program, you can expect enhanced accuracy, streamlined processes, and a robust foundation for maintaining the safety and efficiency of your operations.

CML Data Processing & Inspection Optimization

Integrity EPC Engineering & Data Services team is highly experienced in managing inspection results and field reports to migrate results into any IDMS or analytics platform. Whether migrating inspection data to Blue Hawk® – our proprietary IDMS platform – or any other client environment, our team is proficient in extracting, transforming, interpreting, merging design specifications (i.e., U-1 or pipe specifications), and loading integrity & inspection data.

Our subject matter experts can also help clients select/optimize (CMLs) for either baseline or other inspections, targeting high-risk areas and recommending specific inspection techniques with high probability of detection. CML optimization following a Risk Based Inspection (RBI) program typically returns on average 30-60% reduction in CMLs following successful baseline inspections.

Collection, Analysis, and Maintenance of NDE Data

At Integrity EPC, we specialize in the comprehensive collection, analysis, and maintenance of Non-Destructive Examination (NDE) data to ensure the highest standards of mechanical integrity and operational safety. Our expert technicians utilize advanced NDE techniques to gather critical data. This data is meticulously analyzed to detect potential issues, assess material conditions, and predict remaining life. By maintaining an organized and accessible database of NDE data, such as our Blue Hawk® MI IDMS platform, we enable proactive maintenance strategies and informed decision-making, ultimately extending the lifespan of your assets and minimizing downtime. Trust Integrity EPC to deliver precise, reliable NDE data management that supports the integrity and efficiency of your operations.

Corrosion Study & Damage Mechanism Review

As part of Integrity EPC’s range of corrosion engineering support services, our corrosion specialists help clients identify and assess active Damage Mechanisms (DMs) influencing equipment/systems and help maintain and assure the integrity performance of critical assets. As a result, Integrity EPC develops site-specific, integrated corrosion management strategies to help manage and prevent corrosion utilizing industry relevant codes and standards (API RP 970, API RP 571, API 581).

SERVICE OFFERINGS:

• Data collection, review, gap analysis, and assessment
• Process data
• Operating data
• Design/fabrication data
• Inspection and failure history
• Generation of corrosion materials diagram, preparation of DMR worksheet, and assessment/identification of active DMs using relevant industry codes and standards
• Generation of corrosion loop, unique identification, active DMs and expected susceptibilities and mark-up on PFDs and P&Ids
• Facilitate the DMR workshops, validation, and identify expected corrosion rates with key client personnel and/or stakeholders
• Provide a comprehensive DMR report that contains a simple process description of area, the corrosion concerns, including justification for the chosen DMs and specific areas of interest, as well as any recommendations that are highlighted by the Integrity EPC corrosion team
• Generation of optimized mitigation plans for MI program study against any changes in asset design or operation

Deficiency Program Recording and Management

At Integrity EPC, our Deficiency Program Recording and Management service is designed to systematically identify, document, and address any deficiencies in your mechanical systems, ensuring sustained operational integrity and compliance. Our comprehensive approach involves meticulous recording of all identified deficiencies, coupled with a robust management system that prioritizes and tracks corrective actions. By leveraging advanced technology – such as Blue Hawk® Smart Forms – and industry best practices, we provide a transparent and organized framework for addressing mechanical integrity issues promptly and effectively. Our program not only ensures immediate resolution of deficiencies but also helps in preventing future occurrences, thereby enhancing the overall safety, reliability, and performance of your assets. Trust Integrity EPC to maintain the highest standards of mechanical integrity through our diligent deficiency management processes.

Fitness for Service

Integrity EPC assists clients evaluate degraded equipment/components while in-service and empowers them with the technical information required to make decisions on repair, re-rating or decommissioning. Level I, II, and III quantitative engineering evaluations are performed as per API 579-1/ASME FFS-1 Fitness-For-Service to demonstrate both the pressure retaining and/or structural integrity of in-service equipment components and structures that has a flaw or damage reported.

FITNESS FOR SERVICE APPLICATIONS:

• Damage classification
• General metal loss assessment
• Local metal loss assessment
• Pitting corrosion assessment
• Non-growing crack-like flaw assessment
• Growing crack-like flaw assessment
• Brittle fracture assessment
• Fire damage assessment
• Creep damage assessment
• Fatigue damage assessment
• Misalignment & shell distortion assessment
• Dents, gouges, or dent & gouge assessment
• Laminations assessment
• Pipeline span assessment and FMEA modelling
• Equipment design and suitability for service assessment
• Equipment strategy, piping, and structural FMEA modelling
• FFS procedure strategy and template development
• Equipment piping and structural FMEA modeling

Fixed Equipment Integrity Codes & Design Calculations

At Integrity EPC, we specialize in Fixed Equipment Integrity Codes & Design Calculations, ensuring your mechanical systems adhere to the highest standards of safety and performance. Our team of experienced engineers rigorously applies industry codes and standards, such as API, ASME, and others, to evaluate the integrity of your fixed equipment. Through precise design calculations, we assess factors such as stress, pressure, and temperature tolerances, ensuring your equipment can withstand operational demands. Our comprehensive approach guarantees compliance, optimizes functionality, and enhances the longevity of your assets. Rely on Integrity EPC for expert guidance and accurate calculations that fortify the mechanical integrity of your fixed equipment.

IDMS Management/Upkeep

At Integrity EPC, our IDMS (Inspection Data Management System) Management and Upkeep services are pivotal for maintaining the integrity and performance of your mechanical assets. We ensure your IDMS is meticulously managed and regularly updated, providing a comprehensive and accessible repository of inspection data. Our expert team oversees the seamless integration of new data, routine maintenance, and system enhancements, ensuring the accuracy and relevance of the information. By optimizing your IDMS, we facilitate proactive maintenance planning, regulatory compliance, and informed decision-making. We can deliver robust IDMS management that enhances operational efficiency, minimizes downtime, and upholds the highest standards of mechanical integrity.

Integrity Database Migration & Workflows

At Integrity EPC, our Integrity Database Migration & Workflows services are designed to streamline and enhance the management of your mechanical integrity data. We specialize in seamlessly migrating your existing data to advanced, user-friendly platforms, ensuring data accuracy and continuity. Our expert team develops customized workflows tailored to your operational needs, optimizing data management processes and improving efficiency. By leveraging cutting-edge technology and best practices, we ensure that your integrity database is robust, accessible, and scalable. With Integrity EPC, you can trust that your data migration and workflow solutions will support proactive maintenance, regulatory compliance, and strategic decision-making, ultimately strengthening the integrity and reliability of your mechanical systems.

Integrity RAGAGEP Interpretation & Implementation

At Integrity EPC, we excel in the interpretation and implementation of Recognized And Generally Accepted Good Engineering Practices (RAGAGEP) for mechanical integrity. Our team of seasoned engineers and industry experts meticulously interpret RAGAGEP standards to ensure your operations meet the highest levels of safety and compliance. We provide tailored implementation strategies that integrate seamlessly with your existing processes, ensuring that every aspect of your mechanical systems adheres to these critical guidelines. By partnering with Integrity EPC, you gain access to unparalleled expertise and a commitment to excellence that enhances operational reliability, mitigates risks, and ensures regulatory compliance, thereby safeguarding your assets and optimizing performance.

Mechanical Integrity Procedures

At Integrity EPC, we develop and implement robust Mechanical Integrity Procedures that are essential for maintaining the safety, reliability, and efficiency of your operations. Our comprehensive procedures encompass detailed inspection, testing, and maintenance protocols, ensuring every component of your mechanical systems is thoroughly evaluated and maintained. By adhering to industry standards and best practices, we provide a systematic approach to identify and mitigate potential risks, extend the lifespan of your equipment, and ensure regulatory compliance.

Mechanical Integrity Program Management

Mechanical integrity (MI) programs have proven to be one of the most difficult process safety management (PSM) elements and plant activities to effectively develop and implement. Our professional engineering advisors are MI experts who have the experience and capabilities to help clients overcome this challenge and create an effective mechanical integrity program based on a thorough understanding of regulatory requirements and expectations.
Integrity EPC has helped all types of facilities develop and implement cost-effective and compliant mechanical integrity programs that meet OSHA PSM and EPA RMP regulations as well as other global process safety requirements.

ASSET INTEGRITY PROGRAM DEVELOPMENT:

• Applicable regulations, codes, standards, and recommended practices
• Asset integrity strategy, plan development, implementation
• Documentation requirements
• Quality assurance
• Audit support

• Engineering & software for:

  • Inspection Data Management Systems (IDMS)
  • Mechanical Integrity (MI)
  • Risk Based Inspection (RBI) programs
  • Inspection Test Plan (ITP) development including CML optimization
  • Process Safety Management (PSM)
• Inspection optimization & NDE consulting

Mechanical Integrity Specialist & Engineering Consulting

At Integrity EPC, our Mechanical Integrity Specialist & Engineering Consulting services provide unparalleled expertise and tailored solutions to ensure the optimal performance and longevity of your mechanical systems. Our team of seasoned specialists and engineers brings a wealth of experience in identifying, assessing, and mitigating potential integrity issues. We offer comprehensive consulting services that include detailed assessments, failure analysis, risk-based inspection planning, and customized integrity management programs. By leveraging cutting-edge technology and industry best practices, we deliver actionable insights and strategic recommendations that enhance safety, compliance, and efficiency. Partner with Integrity EPC for expert guidance and innovative solutions that uphold the highest standards of mechanical integrity.

P&ID Review, Circuitization and Inspection Test Plan Creation

At Integrity EPC, we specialize in P&ID (Piping and Instrumentation Diagram) Review, Circuitization, and Inspection Test Plan Creation services to ensure the utmost mechanical integrity of your systems. Our expert team meticulously reviews P&IDs to verify accuracy and completeness, ensuring that all critical components are properly documented. We then create detailed circuitization diagrams that provide clear visual representations of your piping and instrumentation systems, facilitating efficient inspection and maintenance planning. Our tailored Inspection Test Plans are developed to ensure thorough examination and testing of your equipment, adhering to industry standards and best practices.

Review and Create QA Plans

At Integrity EPC, we specialize in the review and creation of Quality Assurance (QA) Plans tailored specifically for mechanical integrity. Our expert team meticulously reviews existing QA plans to ensure they meet current industry standards and regulatory requirements. We work closely with your team to develop customized QA plans that outline comprehensive procedures for inspection, testing, maintenance, and documentation. These plans are designed to enhance the reliability, safety, and efficiency of your mechanical systems, while also ensuring compliance with applicable codes and standards. By partnering with Integrity EPC, you gain access to our deep expertise and commitment to delivering QA plans that support proactive maintenance and strategic decision-making, ultimately safeguarding your assets and optimizing operational performance.

Risk Based Inspection (RBI) & Prioritization

The aim of Risk Based Inspection (RBI) approach is to prioritize the inspection of systems, sub-systems or components based on potential for and consequences of failure. Integrity EPC provides RBI services that help assess the Probability of Failure (PoF) and the Consequence of Failure (CoF) in process units.

Risk Prioritization applies the foundational principles of API 580 and various industry techniques to risk rank assets at a high level for prioritization of relevant tasks or strategic inspection rollout.

RISK BASED INSPECTION PROCESS INCLUDES:

• Data collection
• System, sub-system, corrosion circuit & component identification
• Damage mechanisms & failure modes identification
• Probability of Failure (PoF)
• Consequence of Failure (CoF)
• Risk Ranking
• In-service inspection plan
• Audit
• Client training