Services > Asset Integrity Services
Asset Integrity Services
Facilities evolve. Feedstocks change, operating conditions shift, and equipment accumulates history that its original design basis never anticipated. Cognascents builds asset integrity programs that reflect the facility you actually operate today and the risk profile that comes with it.
Our Approach
Asset integrity and process safety are not separate disciplines.
At Cognascents, they never have been.
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The industry has historically kept asset integrity and process safety in separate silos, served by separate firms with separate technical cultures. The mechanical integrity team handles inspection. The process safety team handles hazard analysis. Rarely do the two talk to each other in a way that produces a complete picture of risk. Cognascents closes that gap. Our engineers work across both disciplines because the risks they manage are not separate. A corrosion mechanism that exceeds an Integrity Operating Window is also a process safety event. An RBI program that does not account for operating condition changes is not just an inspection gap. It is a hazard that has not been identified yet. |
What this means in practice: when you engage Cognascents on an asset integrity program, you are not just getting an inspection plan. You are getting engineers who understand the process side well enough to ask the questions that inspection data alone will not prompt. That combination is rare, and it is the reason clients who work with us in one discipline tend to expand into others. Our engineers act like owner-operators. They take personal accountability for what their findings mean, not just for producing a deliverable that documents them. That is a different kind of consulting, and it shows in the work. |
“The two really should be working hand-in-hand. They should be married, not divorced.”
John Perez, P.E. — Owner & Principal Engineer, Cognascents
When Clients Engage Us
These are the situations that bring asset integrity leaders to Cognascents.
You do not need to be in a crisis to benefit from a program assessment or a fresh set of engineering eyes. But the situations below are the ones we encounter most often.
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Program Gaps Your RBI program is overdue for an update RBI assessments are time-dependent and only as accurate as the data available at the time they were run. If your program has not been updated to reflect operational changes, modified service conditions, new inspection findings, or degradation mechanism reviews, the risk rankings it produces may no longer be reliable. |
Turnaround Planning You need defensible inspection scope decisions before a TA Turnaround windows are expensive and compressed. Inspection scope decisions made on historical intervals rather than current risk can result in both over-inspection of low-risk equipment and under-inspection of equipment that has changed. We help you build an inspection plan that holds up under regulatory and insurance scrutiny. |
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Regulatory Pressure An audit has flagged mechanical integrity gaps OSHA PSM, EPA RMP, and API inspections increasingly scrutinize the quality of mechanical integrity programs, not just their existence. If your last audit produced recommendations you have not closed, or if your program lacks the documentation depth auditors expect, we provide a clear path to remediation. |
Fitness Assessment Inspection findings raise questions about continued service When corrosion, cracking, or other degradation exceeds expected thresholds, the question becomes whether affected equipment can safely continue to operate until the next planned maintenance window. Fitness-For-Service assessments under API 579-1/ASME FFS-1 provide the engineering basis for that decision. |
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Data & Visibility Your inspection data is fragmented across systems Many facilities have years of inspection records spread across multiple systems, formats, and inspection vendors, with no unified view of fleet-wide risk. We help you consolidate, contextualize, and act on that data, including 3D visualization integration with CMMS/EAM and IDMS platforms. |
Operational Changes Your facility has changed but your program has not caught up New feedstocks, process upsets, modified operating conditions, or new units online all introduce damage mechanisms and corrosion risks that may not be reflected in your current integrity program. We assess the gap and update your CCDs, IOWs, and inspection plans to match your current operations. |
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Asset Integrity Services
What we deliver in this practice area.
Each of the services below can be engaged independently or as part of a broader asset integrity program. For most clients, the work expands over time as we develop a deeper understanding of their facilities and risk profile.
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Program Foundation Integrity Program Assessment, Execution, and Optimization A thorough evaluation of your existing asset integrity program against API standards and industry best practices, followed by a prioritized roadmap for improvement and hands-on execution support. |
Inspection Planning Risk-Based Inspection (RBI) API 580/581-aligned RBI implementation that prioritizes your inspection resources based on actual probability and consequence of failure, not calendar intervals. Includes damage mechanism reviews, CML optimization, and inspection planning. |
Corrosion Management Corrosion Control Documents (CCD) & Integrity Operating Windows (IOWs) CCDs that document your facility’s damage mechanisms and corrosion circuits, paired with API 584-compliant IOWs that give operators real-time operating limits to protect equipment integrity before damage accumulates. |
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Fitness Assessment Fitness-For-Service (FFS) Engineering assessments under API 579-1/ASME FFS-1 that evaluate whether equipment with identified flaws, corrosion, or damage can safely continue in service and under what conditions. Backed by engineering judgment and documented for regulatory defensibility. |
Digital Integrity Asset 3D Visualization Laser scanning and 3D modeling integrated with your CMMS/EAM, IDMS, and process historian to create a contextualized, cloud-based view of your asset fleet. Enables better inspection planning, turnaround management, and cross-discipline collaboration. |
Team Development Asset Integrity Training Solutions Instructor-led training programs including RBI the Game, a hands-on team-based course built on API RP 580 principles that develops practical RBI skills through realistic resource allocation scenarios. Available for mechanical integrity engineers, inspection teams, operations, and plant management. |
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Standards & Codes We Work To
Our asset integrity work is grounded in the standards your auditors and insurers will look for.
API 510 — Pressure Vessel InspectionAPI 570 — Piping InspectionAPI 571 — Damage MechanismsAPI 580 — Risk-Based InspectionAPI 581 — RBI MethodologyAPI 584 — Integrity Operating WindowsAPI 579-1 / ASME FFS-1 — Fitness-For-ServiceAPI 653 — Aboveground Storage TanksAPI 970 — Corrosion Control DocumentsASME B31.3 — Process PipingOSHA PSM 29 CFR 1910.119RAGAGEP
Relevant Content
See how this work gets done.
Case studies and technical articles from Cognascents engineers, drawn from real engagements across refining, petrochemical, midstream, and chemical processing.
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Case Study — Refinery Refinery-Wide Integrity Operating Window Development Damage mechanism reviews, corrosion control documents, and IOWs developed from the ground up across all process units for an Oklahoma refinery with outdated and inconsistent existing documentation. |
Case Study — Midstream Risk-Based Inspection Implementation RBI program built for a Canadian midstream operator shifting from calendar-based inspection intervals to API 580/581-aligned risk prioritization. Included 100+ piping circuits, 50+ vessels, and full ABSA regulatory alignment. |
Case Study — 3D Visualization Future-Ready Mechanical Integrity Program with 3D Visualization Laser scanning and 3D digital twin implementation integrated with a client’s CMMS and IDMS to enable contextualized, data-driven mechanical integrity management at the asset level. |
Start with a conversation, not a proposal.
Tell us what you are dealing with. One of our asset integrity engineers will give you a straight answer about whether and how we can help, without a sales process in between.