Mechanical Integrity Engineering 

1-2 Fitness-for-Service & Fracture Mechanical Analysis (API 579)

At iREC, we specialize in conducting Fitness-for-Service (FFS) assessments to determine whether pressure equipment, piping, and tanks can safely continue operation despite flaws, damage, or degradation. Our evaluations are fully aligned with API 579 standards, enabling clients to make evidence-based decisions on asset management. 

We provide: 

• FFS Level 1 Assessments: Rapid, conservative screening methods for initial evaluations. 

• FFS Level 2 Assessments: Intermediate, detailed evaluations using analytical techniques to refine results. 

• FFS Level 3 Assessments: Advanced assessments that incorporate fracture mechanics and finite element analysis (FEA) to address complex flaws and operating conditions. 

Using state-of-the-art tools, our engineering team performs fracture mechanics analysis to evaluate crack growth, residual strength, fatigue life, and critical flaw size. Combined with finite element modeling, this approach delivers highly accurate insights into structural integrity under actual service conditions. 

The result: clients gain a clear, defensible basis for repair, replacement, or continued operation decisions, reducing unnecessary downtime, ensuring compliance, and extending the life of critical assets. 

t iREC, we specialize in conducting Fitness-for-Service (FFS) assessments to determine whether pressure equipment, piping, and tanks can safely continue operation despite flaws, damage, or degradation. Our evaluations are fully aligned with API 579 standards, enabling clients to make evidence-based decisions on asset management. 

We provide: 

• FFS Level 1 Assessments: Rapid, conservative screening methods for initial evaluations. 

• FFS Level 2 Assessments: Intermediate, detailed evaluations using analytical techniques to refine results. 

• FFS Level 3 Assessments: Advanced assessments that incorporate fracture mechanics and finite element analysis (FEA) to address complex flaws and operating conditions. 

Using state-of-the-art tools, our engineering team performs fracture mechanics analysis to evaluate crack growth, residual strength, fatigue life, and critical flaw size. Combined with finite element modeling, this approach delivers highly accurate insights into structural integrity under actual service conditions. 

The result: clients gain a clear, defensible basis for repair, replacement, or continued operation decisions, reducing unnecessary downtime, ensuring compliance, and extending the life of critical assets. 

1-3 In-Service Inspection Program

At iREC, we design inspection programs that protect assets throughout their operational life while ensuring compliance with international safety and integrity standards. Our approach focuses on early defect detection, optimized cost, and minimized downtime, delivering maximum value to our clients. 

We support a wide range of onshore and offshore assets, including pressure vessels, piping, heaters, coolers, fired and unfired heat exchangers, storage tanks, flare tips, platforms, modules, and industrial structures. 

Our engineering team develops tailored inspection scopes to suit operational realities: 

• Develop customised inspection scopes based on susceptible damage mechanisms and in compliance with applicable standards using cost effective methods include 

• Visual Inspection (EVI & IVI),  

• Non-destructive testing (UT, RT, MPI, DPT, ET)  

• Advanced NDT (PAUT, ToFD, PEC, ACFM, RTR, etc.) 

• Tube Inspection (MFL, IRIS, ECT, RFT, NFT, etc.) 

• Drone Inspection (UAV) 

• Thermography,  

• Material Verification (PMI) 

• Insitu-material testing (Hardness, Replica Metallography, etc.) 

• Others 

• Develop Non-Intrusive Inspection scope (NII) as per “HOIS-RP-103” for pressure equipment utilising advanced Non-Destructive Testing (NDT) reducing the need for unnecessary shutdowns. 

• Major turnaround inspections with detailed scopes, ensuring critical equipment is thoroughly assessed during planned outages. 

By integrating advanced inspection techniques with risk-based strategies, we help clients achieve greater asset availability, reduced maintenance costs, and safer long-term operations. 

We help you protect your assets from Day One. By detecting fabrication flaws, coating damage, and handling issues before operations begin, we safeguard reliability, safety, and compliance. Our inspections are aligned with API, ASME, and NACE/AMPP standards—delivering peace of mind, smoother handovers, and a solid baseline for future RBI planning. 

With our service, you gain: 

• Warranty protection – defects are identified before service begins. 

• Faster start-ups – commissioning delays are avoided by eliminating surprises. 

• Lifecycle assurance – “Day-1” condition data supports RBI and long-term integrity. 

• Stronger accountability – vendors remain responsible if issues arise later. 

The result? Lower costs, fewer shutdowns, safer startups, and lasting performance you can trust. 

At iREC, we provide engineering integrity assessments for inspection outcomes of pressure vessels and piping systems to ensure continued safe and reliable operation. Our evaluations are performed in line with international codes and standards (such as ASME, API, and ISO) and are tailored to the specific service conditions of each asset. 

We assess critical degradation mechanisms, including corrosion, fatigue, creep, and mechanical damage, using state-of-the-art methodologies and tools. By combining engineering expertise with proven assessment techniques, we deliver clear, actionable engineering assessment report including: 

• Risk ranking and assessment of reported findings and anomalies 

• Confirming Fitness for Service and safe operating envelop 

• Defining remaining life and required next inspection frequency 

• Necessary repairs or modifications to restore integrity if required 

• Fitness-for-service evaluations for life extension 

• Assessment in compliance with governing standards and client specifications 

With iREC’s evaluations, clients gain the confidence that their pressure equipment and piping systems are managed with the highest standards of safety, reliability, and regulation compliance. 

At iREC, we deliver comprehensive integrity assessments for above-ground storage tanks, ensuring safe operation, extended service life, and full regulatory compliance. Our certified specialists assess structural condition, corrosion progression, foundation settlement, and overall fitness-for-service—identifying risks before they affect your operations. 

By applying API 653 standard rules to tanks built in accordance with API 650 and API 620, We combine modern inspection technologies to provide precise and cost-effective evaluations that: 

• Safeguard stored products and maintain operational reliability 

• Ensure compliance with regulatory and industry requirements 

• Extend asset life through proactive repair and maintenance planning 

• Reduce risk of leaks, failures, and environmental incidents 

Our structured methodology covers all tank types—including fixed roof, floating roof, double-shell, heated, unheated, and transportable tanks—delivering clear insights and actionable strategies for safe, reliable, and environmentally responsible storage tank management. 

At iREC, we help clients establish Integrity Operating Windows (IOWs) following API 584 guidelines — clearly defined safe limits for critical process parameters such as temperature, pressure, flow, and chemistry. By setting and monitoring these boundaries, we ensure assets operate within conditions that preserve integrity and reliability. 

Through advanced asset health monitoring systems, we provide early detection of abnormal trends, allowing operators to act before issues escalate. This proactive approach: 

• Prevents equipment degradation and process upsets 

• Extends the safe operating life of critical assets 

• Reduces the likelihood of unplanned shutdowns or costly failures 

• Enhances compliance with industry best practices and regulatory requirements 

Our integrated IOW and monitoring solutions give clients a powerful tool for risk reduction, operational efficiency, and long-term asset reliability. 

Our team provides end-to-end corrosion and materials engineering solutions to protect assets from premature failure. We address corrosion threats through mitigation strategies, optimized materials selection, and long-term corrosion management planning. 

At iREC, we deliver comprehensive materials and corrosion engineering solutions to protect assets from degradation and premature failure. By addressing corrosion threats with a combination of mitigation strategies, optimized materials selection, and proactive lifecycle planning, we help clients extend asset life, reduce downtime, and ensure compliance with international standards. 

Our services include: 

• Cathodic Protection Validation
  We design, audit, and validate cathodic protection (CP) systems for pipelines, storage tanks, and marine structures. Through field measurements and system audits, we confirm effectiveness and ensure buried and submerged assets are fully protected from corrosion threats. 

• Corrosion Management Plans
  We develop tailored corrosion management plans that integrate inspection data, monitoring systems, and mitigation strategies. These plans provide a structured framework to identify, assess, and control corrosion risks throughout the asset lifecycle, ensuring reliable and cost-effective operation. 

• Fabrication Maintenance Strategies
  Our team provides protection strategies for both fabrication and in-service phases, including advanced coating systems, thermal insulation, and Passive Fire Protection (PFP) applications. These measures improve durability, enhance fire resistance, and safeguard asset performance under demanding service conditions. 

We provide end-to-end engineering support for coating, lining, insulation, and fireproofing systems, ensuring long-term protection of assets in harsh service environments. Our team develops coating and lining specifications aligned with the latest standards while incorporating recently developed, high-performance systems available in the market.  

Where your existing system deteriorates, we assess service conditions and recommend tailored effective solutions designed to improve performance and save cost. Each specification is backed by QA/QC procedures, inspection test plans, and lifecycle cost considerations, delivering durability, compliance, and safety. 

By combining engineering expertise, advanced inspection technologies, and international best practices, iREC ensures that assets remain protected, reliable, and cost-efficient across their entire lifecycle. 

Our engineers design and qualify repair methods in full compliance with ISO and ASME PCC-2 standards. We provide innovative, cost-effective, and safe solutions for temporary and permanent repairs, reducing downtime and extending asset service life. 

We conduct systematic investigations of equipment failures to identify root causes. By applying proven methodologies, we help clients eliminate repeat failures, improve design and maintenance strategies, and enhance overall asset reliability.