Comprehensive In-service Inspection Services

Comprehensive In-service Inspection Services

Optimise your plant’s operational efficiency and upkeep safety

Optimise your plant’s operational efficiency and upkeep safety

WHAT IS in-service inspection services?

As an operator and a plant owner, a well-designed maintenance program to ensure that complex assets consistently deliver the desired output with zero downtime is extremely critical. While doing so, a safe and hazard free workplace, complying to local and international regulatory environment is also of prime importance. As ‘duty of care’ requirements are to be met by owners and operators, a trusted agency to support in-service inspections on a periodic basis and to ensure quality of operational equipment and safety is highly essential. 

WHY IS in-services inspection services IMPORTANT?

It is crucial that operators of critical and capital-intensive industry ensure assets are monitored and maintained periodically to achieve planned efficiencies and productivity. An approach of preventive and predictive maintenance services through in-service inspection delivered by a trusted third party service provider will not only help in early detection but also timely action, mitigating the risk of unplanned downtime and costs associated with it. While doing the above, as an operator you are assured about adhering to international, national and safety regulations ensuing smooth operations and clarity on social accountability.

TÜV SÜD HELPS TO Optimise your plant’s operational efficiency and upkeep safety

As a one-stop solution provider, we provide a comprehensive service portfolio delivered by our qualified in-service inspectors to meet your specific requirements. Our services address the needs of preventive and predictive maintenance, condition monitoring, performance verification, process management, risk and safety management, operational management and render insights and knowledge on best practices to assist you to continuously improve your systems and processes to stay relevant and ahead of changing market, technology and regulatory environment. 


Quick overview of service portfolio

Detailed service portfolio video



  • Asset Integrity Management

    Asset Integrity management (AIM) ensures the desired performance of an asset effectively and efficiently at every stage of its lifecycle. Regular inspections, ongoing maintenance, sufficient managerial support, tests of quality assurance processes and a programme of internal and external audits are vital at every stage, from the design and construction of new plants through to operation, maintenance and decommissioning of existing facilities. This ensures service and performance integrity while protecting health, safety and the environment. We adopt a three-phase approach for Asset Integrity Management. First, we provide the investigation of existing asset management processes, procedures and tools in a mid-term service period (analysis phase); next, our experts assist in implementing optimised procedures as recommended (improvement phase); and lastly, we support you with performance measurement of these activities (stabilisation phase).

  • Inspection Services

    Regulatory bodies and local authorities mandate regular inspections for workplace safety and legal protection in order to ensure safety of work environment and avoid accidents. To help you comply with these mandates, our portfolio includes technical inspection, verification, testing and conformity assessment services during in-service, shutdown, turnaround and maintenance with the help of qualified experts. Our in-service inspection ensures that your business remains sustainable by implementing best-in-class maintenance practices and guaranteeing continued product quality. 

  • Non-Destructive Testing (NDT) Services

    NDT services assist in ensuring plant reliability, safety and conformance mitigating risk of incidents that can cause disastrous accidents that may claim human lives or environmental hazards, attracting a heavy financial penalty. The service also enables you to undertake preventive maintenance and further strengthen your quality control measures. We also have technical expertise and experience to support you in carrying out the challenging conventional and advanced NDT tasks across all relevant fields of applications. 

    Scope of conventional and advance NDT methods:
    Thickness Measurement
    Visual Testing
    Surface/Sub-surface Flaw Detection
    Hardness Testing
    Welding Inspection
    Corrosion Mapping
    Acoustic Emission Testing (AT)
    Heat Exchanger Tube Testing
    Pulsed Eddy Current Testing (PECT)
    Pipeline Inspection using Long Range Ultrasonic Testing (LRUT), 
    Storage Tank Shell and Roof Ultrasonic Thickness Measurement using Magnetic Crawler based Tool
    Above Ground Storage Tank Bottom Plate Testing using Magnetic Flux Leakage (MFL) Testing

  • Acoustic Emission Testing (AT)

    Acoustic Emission Testing (AT) is an NDT method aimed at the detection and localisation of leakage and defects such as cracks or corrosion in pressure equipment, machines, facilities, cranes, bridges and others. The advantage of the method is that defects can be registered before they turn into problems. AT can often be carried out with the fluid transported or stored in pressure equipment and tanks, thus, eliminating the organisational efforts, costs and time involved in opening and emptying tanks or pressure equipment. It is a recommended special test method for periodic in-service inspection and continuous monitoring of pressure equipment. Our experts are qualified to carry out AT according to the EN ISO 9712:2012 standard and have long-standing experience in the field of NDT and address all issues related to the safety, cost-effectiveness and quality of your equipment and provide end-to-end support, from organising and coordinating the tests to documenting the test results with compliance to the relevant laws. To support you further, our specialists also advise you on how to best use the available test methods and special procedures.

  • Risk Based Inspection (RBI)

    Risk Based Inspection (RBI) is crucial for optimising the operation and maintenance of industrial. TÜV-RoiM (Risk-Oriented inspection and Maintenance) is our strategy for developing optimised, cost-effective inspection and maintenance programmes within an asset and risk management context. It is achieved by considering probability and consequence of failures as a result of degradation. We base our qualitative and quantitative techniques on internationally accepted standards and guidelines, and then tailor the solutions to your specific concerns.

  • Failure Analysis

    Failure analysis detects the root cause of the failure mechanism and recommends preventive measures to avoid re-occurrences. As an experienced provider of Failure Analysis services, we combine many related fields under one roof. Our expertise includes materials science and engineering, mechanical calculation, construction, process and system engineering, metallographic and chemical investigations, and electronics, biochemical, electrical, acoustic and surface analyses. Our service also includes statements on the root cause of failure for rehabilitation, repair, prevention of future failure and solutions to interdisciplinary problems. 

  • Process Safety Inspection

    Facilities that deal with hazardous materials, such as chemical and pharmaceutical plants, refineries, oil and gas production installations need to have well designed process in place to prevent fires, explosions and accidental releases. To mitigate these risks, our Process Safety Management (PSM) programmes concentrates on risk management and control of thermal processes, need for good design and engineering of facilities, maintenance of equipment, effective alarms and control points, as well as operation and maintenance. Our experts carry out systematic safety reviews (e.g. HAZOP); as well as services in the field of thermal process safety, fire protection, explosion protection, and ignition due to static electricity sources. We support you with the determination of all relevant material data for safe operation and evaluating the criticality of chemical processes.

  • Functional Safety

    It is important for process industry stakeholders to get an evaluation of the entire lifecycle for their mechanical components and assemblies to ensure they perform with the required levels of safety and reliability. Our experts offer trainings and workshops on the basics of functional safety as well as the evaluation of mechanical components. Applying a qualitative approach to functional safety, we provide support throughout the product lifecycle, from product development and design to development of tests as well as auditing of production and functional safety management. Our service also includes certification of valves to functional safety standards.


Your business benefits

  • As an independent and impartial TIC partner – we will help you identify areas for improvement in your systems, processes and maintenance mechanisms. 
  • We have over 20 years of experience – in the field of functional safety of components for the automation and process industry. 
  • Enhance productivity, operations and efficiency – through our in-service inspection services for various equipment across sectors.
  • Minimise risks and gain certainty – with our support to optimise the maintenance and operation of your assets.
  • Ensure Zero downtime – for your plant with our preventive and predictive in-service inspection and maintenance services.
  • Ensure safe working environment – and minimise the risk of safety incidents for your projects with regular maintenance and overhaul. 
  • Instill stakeholder confidence – in your systems and processes by avoiding hazardous accidents and improving quality and safety. 
  • Comply with local and international regulatory requirements – for safety of workforce at the plant site by ensuring that all equipment is functional and in order.
  • Measure equipment durability and performance – with the help of our seasoned experts and cutting-edge technology
  • Work with an expert partner – through the systematic involvement of our experienced teams in all aspects of operational safety and integrity.
  • Strengthen your competitive edge – by partnering with a globally renowned third-party service provider that has a reputation for quality and safety.
  • Benefit from our holistic approach – and enhance your operational efficiency and safety with inspection plans that mitigate technical, structural and environmental risks.
  • Tailor your solutions – with our customer focused solutions and tailored inspection plans designed for the specific needs of each asset.

Why Choose TÜV SÜD?

Our reputation as an independent third-party technical in-service inspection service provider ensures reliability of equipment and mitigates the risk of accidents and safety incidents. We offer a wide range of in-service inspection services to maximise your plant’s effective maintenance and operations. We support you with extensive experience accumulated from international, public, private and joint sector projects, coupled with an in-depth familiarity with all relevant local directives and standards. Our certified and qualified in-service inspectors ensure that both your owned and leased equipment and components continue to operate seamlessly without unscheduled and costly downtimes. Performance verification ensures that new and recurring issues with the equipment are detected and corrected in time. Considered authorities in the field of inspection, our experts proactively participate in the preparation of national and international directives and standards governing effective plant operation and safety.

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