Fabrication & Pre-Service Inspection

An asset integrity management (AIM) system is only as strong as its weakest link. For example, inaccurate data from engineering assessments and inspections, as well as poor quality maintenance and repairs, can have serious financial and safety implications. These can result in unnecessary or premature inspections, maintenance and repairs, asset failures, or loss of production.

We appreciate the significance of how each AIM component and function interact and affect each other, and the outcome. Our highly skilled personnel conduct services in accordance with our specific procedures, ensuring quality and repeatable data. This allows us to accurately predict and plan future AIM activities.

Next Advanced Solutions offers all AIM services, including:

• Integrity engineering
• Corrosion engineering
• Inspection engineering
• Inspection & NDT
• Access
• Maintenance
• Construction
• QA/QC

We offer these services on ad-hoc, project, campaign, or life cycle basis.

Next Advanced Solutions provides integrity engineering services for all stages of an asset’s life cycle. Our services deliver cost-optimised plans to suit your operating requirements and restrictions.

We can assist in evaluating/auditing existing AIM systems, implement our advanced AIM system (COMPASS), as well as provide optimisation solutions to make your existing AIM system more efficient. Our integrity engineering services include, but are not limited to:

• Integrity management
• Integrity management gap analysis
• Risk-based inspection (RBI) and facility risk profiling
• Integrity operating window (IOW) assessments
• Non-intrusive inspection evaluation and management
• Advanced inspection and monitoring data analysis, including:
  • Fitness-for-service
  • Statistical assessments
  • Remaining life assessments
• Life-extension assessments

Next Advanced Solutions collaborates with Dr Edward Cripps to advance on state-of-the-art inspection data analysis methods. Dr Cripps is a Senior Lecturer at the School of Mathematics and Statistics and a member of the Center of Applied Statistics, University of Western Australia (UWA). Dr Cripps is also a co-founder of the Complex Modelling Group, Faculty of Engineering, Computing and Mathematics, UWA.

Assets and asset components are manufactured in accordance with design and fabrication codes and standards. However, these codes do not provide rules for evaluating equipment that contain flaws. To demonstrate the structural integrity of an in-service component that contains a flaw, fitness-for-service (FFS) assessments need to be conducted.

A flaw or defect in a component does not necessarily mean that the asset or component is no longer fit to perform its design intent. Using the FFS module in COMPASS, we can conduct most FFS assessments on-site and our inspection personnel can instantly determine suitability for continued operation. This prevents unnecessary, rushed or costly repair jobs.

FFS assessments are performed in accordance with codes or standards, e.g. API 579-1/ASME FFS-1. This comprehensive FFS standard specifies three levels of assessments for a number of different damage types, each with specific data and qualification requirements.

Assessments are high-level and conservative. NAS inspection personnel conduct these on-site for quick evaluations.

Assessments are detailed and can require more data. Depending on requirements, these assessments are conducted either on-site or off-site. NAS inspection personnel are familiar with FFS requirements. In most cases, they can obtain the required inspection data without the need for additional inspection mobilisation.

Assessments are comprehensive. They require detailed data and utilise finite element analysis (FEA) to determine the outcome.

Corrosion is one of the leading causes of asset failure. It can lead to unmeasured expenses in terms of production loss and reduced asset service life.

Next Advanced Solutions offers quality corrosion engineering services. These services create increased understanding of facility threats and assist in determining optimal monitoring and mitigation specifications. These services include, but are not limited to:

• Corrosion management plan (CMP) (development, auditing, review, optimisation)
• Corrosion risk assessments (CRA)
• Risk-based inspection (RBI)
• Integrity operating window (IOW) assessments
• Corrosion modelling
• Circuitisation (corrosion loop) evaluations
• Optimal condition monitoring locations (CMLs / Hot Spots)
• Corrosion monitoring (probes, coupons, sampling)
• Non-intrusive inspection evaluations
• Process assessments
• Material selection evaluation and recommendation
• Coating evaluation and recommendation
• Chemical dosing evaluation and recommendation

This includes consultancy, independent expert advice, and peer review services (such as IMPACT Plus) provided by Dr Rolf Gubner, who joined our team in December 2020.

Dr Gubner is the first, and currently only, qualified NACE International IMPACT Plus navigator in Australia. IMPACT Plus is a one-of-a-kind, innovative product that enables asset owners to validate corrosion control actions by business impact and maintain a successful corrosion management plan.

Inspections are carried out to determine the physical condition of an asset. To obtain the correct information in the most cost-effective manner, customised inspection plans need to be developed in accordance with equipment risk, acting damage mechanisms, as well as expected damage location and morphology.

Our inspection engineering services provide the framework to acquire accurate and repeatable data. Complemented by our inspection engineering services, our AIM system uses advanced and unique measures to successfully manage data and accurately predict future integrity activities (e.g. maintenance, repair or inspections).

We have comprehensive experience in developing customised inspection plans and offer quality inspection engineering services to develop, implement and execute inspection campaigns. These services include, but are not limited to:

• Inspection management
• Inspection management auditing
• Inspection method evaluations
• Non-intrusive inspection evaluations
• Risk-based inspection (RBI) assessments
• Written scheme of examination (WSE) development
• Inspection scope and work-pack development
• Project management

Inspection services
Non-destructive testing (NDT)
In-service inspections
Baseline inspections
Fabrication and pre-service inspections
Lifting equipment inspections
Class surveys

Assets are governed by a number of codes and standards that specify requirements and thresholds that cannot be exceeded without jeopardising the integrity of the asset.

Next Advanced Solutions has comprehensive experience in national and international codes and regulations for both fabrication/construction and in-service inspection requirements. We develop code compliant inspection plans to efficiently identify and accurately quantify deterioration and defects/anomalies.

Successful completion of inspection campaigns or work-scopes requires detailed planning. We have extensive experience in inspection plan and work-scope development and can manage or support your project requirements to ensure effective execution.
To ensure quality results, we:

• Use qualified inspection and non-destructive testing procedures.
• Develop and qualify application-specific procedures.
• Require mandatory verification of competency of personnel.

Next Advanced Solutions offers highly qualified and experienced inspectors and NDT technicians, as well as state-of-the-art inspection technology to conduct inspections at any stage of an asset’s life cycle. These services include, but are not limited to:

• Plant inspection
• Visual inspection
• Remote camera inspection
• Non-intrusive inspection (NII)
• Non-destructive testing (NDT)
• Structural surveys
• Class surveys
• Derrick inspection
• Lifting equipment inspection
• Drill-handling tool inspection
• Weld inspection
• Code compliance verification (e.g. pipe schedule, flange ratings, etc.)
• Positive material identification (PMI)

To further ensure quality, Next Advanced Solutions collaborates with ’Training & Consultancy Services in Non Destructive Testing’ (TCSNDT) for independent verification of procedures, and competency verification of our NDT personnel.

Each NDT method has its strengths and limitations. Selecting the appropriate NDT method for the application is important to obtain accurate and repeatable data that comply with standards such as AS, ASTM, ASME, BS, AWS or API. We optimise inspection resources by combining NDT technologies and methods to obtain the optimal balance of cost, speed and precision.

We have extensive experience with the latest NDT technologies and have successfully trialled and implemented conventional and advanced techniques on a range of in-service applications. These include a number of phased array and time of flight diffraction technologies for corrosion mapping and weld inspection.

Next Advanced Solutions offers highly qualified and experienced inspectors and NDT technicians, as well as state-of-the-art inspection technology to conduct inspections at any stage of an asset’s life cycle. These services include, but are not limited to:

• Phased array ultrasonics (PA)
• Time of flight diffraction (ToFD)
• Ultrasonic testing (UT)
• Magnetic particle inspection (MPI)
• Eddy current inspection (ECI)
• Dye penetrant inspection (DPI)
• Hardness testing
• Positive material identification (PMI)
• Ferrite testing
• Thermal imaging
• Visual and remote visual inspection

In-service inspections of pressure equipment (pressure vessels, piping, relief valves, heat exchangers, etc.) are conducted to identify and quantify deterioration and anomalies. The results are used to determine whether an asset is fit for continued operation, as well as providing data for continuous monitoring, analysis and prediction.

To increase production uptime, Next Advanced Solutions substitutes intrusive internal inspections with non-intrusive inspections whenever possible.

Next Advanced Solutions offers highly qualified and experienced inspectors (API/AICIP) and NDT technicians, as well as state-of-the-art inspection technology to conduct inspections at any stage of an asset’s life cycle. These services include, but are not limited to:

• Non-intrusive inspection (NII)
• Internal visual inspection (IVI)
• External visual inspection (EVI)
• Non-destructive testing (NDT)
• Corrosion under insulation (CUI)

In-service inspections are also provided for:

• Lifting equipment
• Drill-handling tools
• Derrick inspection
• Structural surveys
• Class surveys
• Dropped objects surveys

Combine our inspection services with rope access solutions to achieve safe, efficient and cost-effective project execution.

A pressure vessel is a closed container designed to hold gases or liquids at a pressure substantially different from the ambient pressure. The pressure differential is dangerous and fatal accidents have occurred in the history of pressure vessel development and operation.

Consequently, pressure vessel design, manufacture and operation are regulated by engineering authorities backed by legislation.

Statutory internal inspections often drive facility or system shutdowns. Where possible, Next Advanced Solutions substitutes intrusive internal visual inspections with non-intrusive inspections to achieve the following benefits:

• Increasing production uptime (shutdown only when needed).
• Eliminating the impact on equipment caused by process shutdown and start-up.
• Reducing risk to personnel by eliminating the need for confined space entry.
• Eliminating mechanical damage to internal protective surfaces (coating).

Replacing internal visual inspection (IVI) with non-intrusive inspection (NII) requires adequate technical justification. Next Advanced Solutions complies with DNV recommended practice (DNV-RP-G103) to determine the applicability of NII methods.

Next Advanced Solutions’ multidisciplinary team of leading specialists provide detailed assessments and results for confident justification and execution of NII. Furthermore, our asset integrity management system includes a guidance system to determine the feasibility of NII, as well as NII life cycle management.

Lifting equipment are the tools and attachments required when lifting or lowering loads. Lifting equipment must be well maintained, sufficiently strong and suitable for the proposed use. Multiple equipment types are covered including cranes, monorails, pad eyes, chain hoists, lifted equipment, slings, shackles, hooks, clamps, sheave blocks, etc. Regulations and standards determine the certification requirements for lifting equipment.

Next Advanced Solutions implements a range of specific inspection procedures to ensure effective examination. We manage all data and examination requirements in our asset integrity management system COMPASS. This enables efficient examination and reporting, as well as client access to completed reports and upcoming inspection requirements.

Our highly qualified and experienced inspectors and NDT technicians, as well as state-of-the-art inspection technology, ensure that your lifting equipment is fit for purpose, in accordance with applicable codes such as NATA or LEEA. The services include, but are not limited to:

• Visual inspection
• Non-destructive testing (NDT)
• Dimensional verification
• Load testing
• Recertification

Class surveys are conducted to ensure compliance with technical standards for the construction and operation of ships and offshore structures. It has become common practice for classification societies such as ABS, DNV, Lloyd’s Register, etc. to utilise rope access to access structures, carry out inspections, and report findings to the class surveyor.

We have extensive experience in planning and execution of class surveys including project management, development of reporting structures in accordance with the respective class society requirements, as well as rope access, inspection and non-destructive testing (NDT). We provide safe and efficient project execution with minimal disruption to operation.

We can conduct in-situ maintenance and repair of class-related non-conformances including structural repairs, hull coating maintenance, cathodic protection replacements, and more.
Next Advanced Solutions offers highly qualified personnel as well as state-of-the-art inspection technology to conduct and support class surveys. These services include, but are not limited to:

• Rope access
• Visual inspection
• Remote camera inspection
• Non-destructive testing (NDT)

Baseline inspections are commonly used for code compliance verification, however, they also provide excellent opportunities to initiate a corrosion monitoring database.

We understand the importance of accurate baseline data and the effect it can have on prediction accuracy and integrity resource allocation.

Prediction of inspection, maintenance and repair activities require detailed knowledge on deterioration rates. Common practice can include using nominal wall thickness as a replacement for accurate baseline measurements. However, large variations (i.e. mill tolerance) can occur, resulting in inaccurate deterioration rates, incorrect scheduling of activities and significant increased life cycle cost.

With asset life cycle cost in mind, long-term benefits can be achieved when baseline inspections are performed correctly. Prior to baseline inspection, Next Advanced Solutions determines the optimal condition monitoring locations based on potential damage mechanisms and employ specific inspection procedures to ensure accurate and repeatable data.

Next Advanced Solutions offers highly qualified and experienced inspectors and NDT technicians as well as state-of-the-art inspection technology to conduct baseline inspections. These services include, but are not limited to:

• Code compliance verification (e.g. pipe schedule, flange ratings, mill tolerance, etc.)
• Positive material identification (PMI)
• Condition monitoring locations (CML)
• Inspection isometrics
• Non-destructive testing (NDT)

Various access solutions are required when conducting inspection, maintenance and construction tasks. Conventionally, access has been provided by scaffolding. However, in certain circumstances it can be safer, as well as more more efficient and cost-effective, to use other access solutions, such as rope access.

Our experienced access team understands the limitations and capabilities of individual and combined access solutions. For example, a valve located high above deck/grade requires a stable platform when performing repairs or maintenance. By utilising rope access instead of erecting scaffolding from the ground up, an isolated scaffold can be constructed around the valve, which reduces man-hours and scaffold tonnage.

Next Advanced Solutions offers a range of safe, efficient and cost-effective access solution services to assist in inspection, maintenance, repair and construction activities. These services include, but are not limited to:

• Detailed access surveys
• Developing project access plan
• Developing facility access plan

• Rope access (in accordance with IRATA guidelines)
• Tension netting
• Scaffolding
• Confined-space entry
• Stand-by rescue

Maintenance and repair processes ensure that an asset can maintain its design intent. Our AIM system, COMPASS, analyses vast amounts of integrity data to develop prioritised maintenance plans including scope and schedule of the required tasks. This allows for reduced maintenance life cycle costs through the prevention of premature maintenance, unnecessary repair, and asset failure.

Next Advanced Solutions offers maintenance engineering and planning services which reduce the costs of maintenance and repairs throughout the life cycle of an asset. These services include, but are not limited to:

• Maintenance management
• Developing maintenance scope and scheduling
• Developing maintenance work-packs (including access specifications)
• Developing code compliant repair plans for pressurised equipment
• Developing qualified maintenance and repair procedures (e.g. weld, coating, etc.)

Quality maintenance and repairs prolong asset service life, resulting in reduced life cycle costs. Next Advanced Solutions provides quality maintenance and repair services, as well as access and QA/QC services, to ensure that quality requirements are met. Maintenance services include, but are not limited to:

• Hydro / grit / sandblasting
• Painting / coating removal or application
• Cutting / grinding
• Welding / steel renewals
• Mechanical fitting

Next Advanced Solutions provides construction services at various project stages ranging from commissioning, via mechanical installations and replacements, through to de-commissioning.

Our construction services assist in efficient and cost-effective project execution. These services include, but are not limited to:

• Installation and mechanical fitting
• Replacements (spool pieces etc.)
• Technical rigging
• Bolt tensioning / torqueing
• Welding
• Non-destructive testing (NDT)
• QA/QC
• Project management

QA/QC is the combination of quality assurance (the process or set of processes used to measure and assure the quality of a product) and quality control (the process of meeting products and services to consumer expectations).

At Next Advanced Solutions, we do not underestimate the importance of effective QA/QC. We understand how sub-standard performance such as poor quality welds or coating applications can result in costly, undesirable events in service. Our procedures and services ensure quality workmanship.

We offer experienced QA/QC engineers, technicians, weld inspectors, coating inspectors and support personnel to various industry sectors. Our personnel can be included within the client project team or be supplied on an ad-hoc basis. The services include, but are not limited to:

• Quality management
• Auditing
• Quality plan (QP) development in compliance with applicable codes and standards
• Inspection and test plan (ITP) development
• Welding procedure specification (WPS) review and compliance verification, and
• Procedure qualification record (PQR) review and compliance verification
• Material test record (MTR) review and compliance verification
• Manufacturer’s data record (MDR) compilation and review, or
• Manufacturer’s record book (MRB) compilation and review
• Source inspection of both vendors and suppliers
• Weld inspection, including fit-up and alignment
• Dimensional verification
• Coating inspection
• Factory acceptance testing (FAT) and witnessing