Megarme on safer inspections and smarter asset maintenance in the GCC

Exclusive interview with Diego Parra, Managing Partner, Megarme

How are oil and gas companies in the GCC changing the way they inspect and maintain their equipment and infrastructure?

We see a stronger emphasis on equipment condition and the consequences of failure when operators plan inspection. Scheduled inspections remain important, alongside operating history, service conditions and the role each asset plays in the operation.

Two similar pieces of equipment may need different inspection plans because their service conditions, exposure or importance to the operation are different. A critical process line, for example, may require a different approach from a low-consequence utility line. The inspection method, coverage and timing should reflect those differences while meeting the applicable requirements.

Inspection history and equipment monitoring can help maintenance teams identify changes early enough to investigate and plan work. This is particularly useful offshore or where access depends on a shutdown, because arranging people, equipment and materials can take time.

At Megarme, we support this approach by providing condition information from the locations included in the inspection scope. Our findings help the operator and its engineering team decide what needs attention, what requires further assessment and what can be included in a planned maintenance campaign. We aim to make the findings clear enough to support those decisions.

What are the biggest challenges companies face when inspecting and maintaining offshore and onshore facilities, and how does Megarme help address them?

A practical challenge is obtaining a reliable assessment while working within the facility’s operating constraints. Access, process safety and inspection quality have to be planned together. The easiest location to reach may not be the one most likely to deteriorate.

Offshore, marine corrosion and possible fatigue at connections subject to repeated loading need attention. Weather windows, restricted deck space and transport arrangements also affect the work. Under-deck steelwork, derricks and flare structures can be demanding, particularly when inspection must be coordinated with lifting or other activities nearby.

Onshore, congested pipe racks, hot surfaces and operating process systems can restrict access. Isolation requirements and shutdown schedules often determine when work is possible. Entry into tanks or vessels introduces additional atmospheric and rescue considerations.

We help by planning the access and technical work together. An under-deck survey may require surface preparation, thickness measurements and weld examination before the engineering team can assess the findings and approve repairs. Identifying these dependencies early helps the operator prepare the work.

Our reports need to make inspection coverage and limitations clear. Work during operation is considered only where the process conditions, risk assessment, permits and required isolations allow it.

How does rope access help Megarme carry out inspection and maintenance work in hard-to-reach areas safely and efficiently?

Rope access allows us to position a qualified technician directly at the work location, including beneath a jetty, beside an elevated pipe support or at a derrick connection. For localised inspection and repair, it can reduce the access structures, material handling and space required.

We are an IRATA Operator and Trainer member. The normal rope access arrangement uses two independently anchored lines: a working line and a safety line. An IRATA Level 3 supervisor oversees the rope access safety arrangements, including equipment checks, rope protection, communication and a rescue plan suited to the location. Team size must support both the task and a potential rescue.

Our technicians also need the qualifications and authorisations for the work being performed. Rope access competence is separate from competence in NDT, welding or coating inspection. An ultrasonic examination carried out on ropes must meet the applicable inspection requirements, including calibration, surface preparation, probe positioning and coverage.

We select the access method around the task, duration, equipment loads and rescue requirements. Depending on the work, that may involve rope access alone or a combination of access arrangements. The practical benefit is being able to reach the required locations with a method suited to the inspection or repair.

How does Megarme use non-destructive testing (NDT) to identify corrosion, cracks and other damage before they become serious problems?

We use NDT to assess remaining wall thickness and look for indications of cracking or other damage. We select the method to suit the material, expected deterioration and inspection requirements.

For pipework corrosion, ultrasonic measurements establish wall thickness at the inspected locations. If we find an unusually low reading, we verify it, promptly raise any critical concern and extend the examination as required to establish the extent of the thinning. Corrosion mapping can provide more detailed coverage where localised attack is suspected. The lowest measured thickness and size of the affected area matter, because an average can conceal a severely thinned location.

Magnetic particle testing can reveal surface and near-surface discontinuities in ferromagnetic materials, such as carbon steel. Penetrant testing can reveal discontinuities open to the surface in suitable nonporous materials. Ultrasonic testing, including phased array, and radiography can be used to examine welds for internal discontinuities. Selection depends on the expected damage, component geometry and applicable requirements; each method has limitations.

We record the component, examination location, coverage, measurements and relevant images or scan data. The findings support the responsible engineer’s decision on further assessment, monitoring or repair. Repaired welds are re-examined as required by the applicable procedure and acceptance criteria. Qualified personnel, suitable procedures and prompt reporting are essential to making the results useful.

How do extreme heat, humidity and salt exposure in the Gulf affect industrial equipment, and what can companies do to protect their assets?

In the UAE and Saudi Arabia, asset protection has to reflect the location. Offshore and coastal facilities face salt exposure and periods of high humidity alongside heat. Further inland, heat and dust become more prominent considerations. The protection system must suit both the local exposure and the equipment’s operating conditions.

We pay particular attention to pipe supports, bolted connections, undersides of structures and insulated pipework. Corrosion can develop in a small, critical area while the wider structure appears acceptable. Moisture entering through damaged insulation cladding can remain against the steel, making targeted inspection and repairs to water-entry points important.

Coating performance depends on preparation and application. Salt, dust and other contamination must be controlled to the specified cleanliness limits, with the required surface preparation and coating thickness verified. Steel temperatures in summer can exceed a product’s application limits. Cooler hours still require checks for humidity and condensation. Some specifications require the steel to remain at least 3°C above the dew point, alongside the product’s other temperature and humidity limits.

Our inspection, surface preparation, coating and repair work can help address deterioration and its causes. Metal loss needs assessment and, where required, an approved repair before protection is reinstated. Leaving a water trap or damaged insulation seal in place can expose the asset to the same problem again.

How does Megarme help oil and gas operators extend the life of their assets while maintaining safety standards?

We support asset life extension by gathering inspection evidence and carrying out approved maintenance or repairs. The starting point is understanding the condition of the equipment, the extent of any damage and its significance for continued operation.

For pipework, thickness measurements and corrosion mapping provide information for assessing metal loss. Our access capability helps reach components that would otherwise be difficult to examine or replace. The inspection scope needs to reflect the expected damage and provide the information required for the engineering assessment.

Our maintenance and repair scope can include surface preparation, coating, work on columns and piping, structural welding and composite repairs, where appropriate to the assessed condition and approved scope. Composite repairs require an engineered design approved for the specific damage and service conditions, controlled installation and the required inspection and verification. Completed work needs the specified quality records before acceptance.

Life extension also requires a plan beyond the immediate intervention. The operator needs to know what should be monitored, when further inspection is required and which operating limits apply. We contribute inspection data and execution capability. The responsible operator and engineering authority determine fitness for continued service and approve any extension of operating life.

What steps does Megarme take to protect workers when carrying out inspection and maintenance work in challenging environments?

We plan our work around a task risk assessment, competent supervision, personnel fit for the assigned work and the facility’s permit requirements. The controls must be confirmed at the worksite, and any change in scope or conditions requires reassessment.

At operating facilities, this includes verified energy isolation, atmospheric testing and monitoring as required, and controls for hazards such as hydrogen sulphide or flammable atmospheres. We seek to avoid confined-space entry where a suitable alternative exists. Where entry is necessary, the arrangements must address unsafe oxygen levels and other identified hazards, with suitable ventilation, communication and a rescue plan specific to that space.

At height, we consider the people below as well as the technicians. Tools need suitable retention and checked attachment points, with exclusion zones appropriate to the task. Heavy equipment requires its own handling and securing arrangements. Accounting for tools when work is complete helps prevent a later dropped-object hazard.

Our heat management arrangements need to reflect the site conditions, workload and protective clothing. The assessment guides acclimatisation, work and rest arrangements, hydration and access to shaded or cooled recovery areas.

We expect personnel to stop work when conditions are unsafe. Supervisors must respond to fatigue, changing weather and any condition that compromises the controls or rescue arrangements.

How are new technologies changing the way oil and gas companies inspect equipment and plan maintenance?

Technology can improve inspection coverage and the speed at which information reaches maintenance teams. Across the industry, drones can support visual surveys, robots can carry sensors across suitable surfaces, and permanent monitoring can identify changes between periodic inspections. Their suitability depends on the asset and the information required.

Encoded ultrasonic scanning is a practical example. It links measurements to their positions, allowing wall loss to be mapped and compared with later examinations when the scan locations and measurement conditions are comparable. Digital records can connect those results with the asset reference, earlier findings and repair history.

We assess a technology by the information it provides and the decision it supports. A visual image may identify an area for closer examination. Confirming wall loss or characterising a defect requires a method suited to that task. AI tools can assist with screening where their performance has been validated for the intended use, with qualified personnel reviewing the results.

Our priority is to select methods that suit the component and expected damage, and to produce clear, traceable records. We use inspection findings to plan any further examination and support the engineering assessment and approval of required repairs.

How can companies reduce maintenance costs and downtime without compromising safety or equipment reliability?

Better preparation and fewer repeat interventions can help control maintenance costs and downtime. The cost of a task includes access, mobilisation, materials, permits, isolation, production disruption and verification. These need to be considered together when comparing ways to execute the work.

Before a shutdown, available inspection findings should be used to define repair scopes, prepare materials and spare parts, agree procedures and secure the necessary personnel. Operations, engineering and maintenance teams need to resolve dependencies early. Discovering that a repair needs additional materials or approval after equipment has been shut down can put the programme under pressure.

We help by coordinating compatible activities within an access campaign. Elevated steelwork, for example, may need condition assessment, NDT, a dropped-object survey and authorised coating repairs. When safely sequenced, these activities can share access arrangements and reduce repeat mobilisation. Required approvals and inspection hold points still apply.

Prompt decisions on findings and investigation of recurring defects also help prevent delay and rework. Useful performance measures include total maintenance cost, unplanned downtime, repeat failures and closure of critical findings. Any cost-reduction plan must preserve required inspections and the maintenance and testing of safety-critical equipment.

What are the main inspection, maintenance and safety challenges you expect the GCC oil and gas industry to face over the next few years, and how is Megarme preparing for them?

We expect an important challenge to be balancing maintenance of operating assets with inspection needs during construction and commissioning. When shutdowns and project activities overlap, there can be pressure on the availability of experienced personnel and technical supervision.

Advanced NDT technicians, welding and coating inspectors, and rope access supervisors need the competence and approvals for each assignment. Our preparation includes attention to training, personnel allocation and the technical support available to site teams. Resources need to match the work being accepted.

The quality of records handed over from construction to operations is another priority. Traceable weld records, baseline thickness measurements and coating inspection results give maintenance teams a useful starting point. Consistent component identification helps later inspection results be compared with the correct earlier records.

For existing facilities, corrosion in difficult-to-access areas and beneath insulation will continue to require attention. On safety, overlapping inspection, lifting and hot work need careful coordination. Heat exposure and fatigue also need to be reflected in staffing and schedules.

We are focusing on consistent technical review, equipment readiness and clear reporting across our regional operations. Our aim is to keep the standard of execution consistent as workloads change, with appropriate supervision and follow-up on significant findings.