Asset Integrity Management for Small-to-Midsize Facilities: Where to Begin
Asset integrity management (AIM) is often viewed as a resource-heavy process, something reserved for large facilities with dedicated integrity teams and big budgets. In reality, smaller operators face many of the same challenges: corrosion, aging infrastructure and operational stresses.
AIM isn’t just about checking boxes for compliance. It’s a structured approach to ensuring that physical assets such as pipelines, tanks, pressure equipment, civil structures, and electrical systems perform their intended function safely, reliably, and efficiently over time. For small-to-midsize operators, starting an integrity program doesn’t need to be complicated or expensive. What’s needed is a smart, scalable plan built on prioritization, practicality, and steady progress.
Beyond the Basics: What Does Asset Integrity Really Involve?
While common starting points include cathodic protection (CP), coatings, non-destructive testing (NDT), and risk-based inspection (RBI), a comprehensive AIM framework also considers:
Mechanical integrity (including piping and pressure equipment)
Structural integrity (civil, concrete, and steel infrastructure)
Material selection and degradation mechanisms
Stray current and electrical interference risks
Process safety elements (valves, relief devices, instrumented systems)
Documentation and data governance
Inspection record management and trending
Failure analysis and root cause reviews
Personnel competency and training
Even a basic program should touch on each of these areas over time, prioritizing based on risk, asset criticality, and available resources.
Step 1: Build an Asset Register
Start by creating a centralized asset register, a structured list of key assets with basic attributes:
Asset name and location
Type and material
Age (or installation year)
Service environment
Access constraints
Consequence of failure (CoF)
Step 2: Perform Targeted Field Assessments
Using your asset register and CoF ratings, prioritize fieldwork for high- and medium-risk assets. Focus on cost-effective, high-yield assessments:
Cathodic Protection & Coatings
Perform pipe-to-soil potential measurements
Check rectifier function and current output
Visually inspect coating on accessible piping and tank exteriors
Identify signs of shielding or underfilm corrosion
Non-Destructive Testing (NDT)
Use ultrasonic thickness (UT) on older piping
Apply magnetic particle testing (MT) or dye penetrant (PT) at welds and supports
For insulated or buried assets, consider guided wave UT or pulsed eddy current (PEC)
Structural & Civil Elements
Inspect for corrosion, cracking, spalling, and water ingress
Pay special attention to supports exposed to cyclic loads or poor drainage
Electrical Interference & Stray Current
In transit-adjacent facilities, measure for stray DC or AC voltages
Assess the impact of nearby substations, rail systems, or grounding networks
Step 3: Assign Probability of Failure and Prioritize
With field data in hand, assign initial PoF values using inspection results, observed damage, or known issues. The combination of CoF and PoF forms your risk matrix.
Example:
Pipeline under a road crossing with no CP current, High CoF, Medium PoF → High Risk
Aboveground tank with aged coating but no damage, Medium CoF, Low PoF → Medium Risk
Use the matrix to develop a prioritized action list—repairs, monitoring upgrades, or follow-up inspections.
Step 4: Plan for Remediation and Monitoring
For high-risk items:
Design rehabilitation immediately and continue to monitor
For medium-risk items:
Plan recurring inspections at defined intervals (e.g., 2–3 years)
Document deterioration trends over time
For low-risk items:
Maintain documentation and monitor for changes in environment or service
Step 5: Formalize and Improve Over Time
Once your integrity program is functioning, formalize it with repeatable processes:
Define inspection intervals based on risk
Use standard forms for visual inspections, CP readings, and NDT reports
Store records in a centralized location (even if it's a shared folder)
Over time, update the asset register with findings, refine PoF scores, and adjust mitigation priorities. This iterative approach builds institutional knowledge and creates a sustainable cycle of continuous improvement.
Why This Works
We’ve worked with small utilities, municipalities, and operators who took this risk-focused approach and achieved major benefits:
Fewer reactive repairs and unplanned outages
Better justification of maintenance budgets to leadership
Easier conversations with regulators and insurers
Small operators often feel stuck between operational demands and limited resources. But integrity management doesn’t need to be perfect—it just needs to be prioritized. A lean, risk-based approach allows you to start where you are and scale over time.
Don’t wait for failure. Start with an asset register, assess high-risk components, and build a practical integrity plan from there.
If you need help structuring or executing your program, Zenith Integrity offers advisory and technical services tailored for resource-limited environments—with real-world experience in buried pipelines, CP, transit systems, and structural durability.
Asset & Maintenance Management Transformation Case
These transformations reduce risk, improves performance and reduce cost. Let Zenith Integrity help your firm get to a world class level with your asset and maintenance management.