Key Responsibilities and Required Skills for Integrity Inspector

🎯 Role Definition

An Integrity Inspector is responsible for planning, executing, documenting and reporting physical and nondestructive inspections to ensure structural, operational and regulatory integrity of pipelines, storage tanks, pressure vessels and associated infrastructure. The role emphasizes safety, compliance with industry standards (API, ASME, PHMSA, DOT), identification and mitigation of corrosion and integrity threats, and coordination with operations, engineering and integrity management teams to support risk-based inspection and asset management programs.

📈 Career Progression

Typical Career Path

Entry Point From:

Field Technician — Inspection or Corrosion Technician
NDT Technician (Level I/II) or Pressure Equipment Technician
Pipeline Operator or Maintenance Technician

Advancement To:

Senior Integrity Inspector / Lead Inspector
Integrity Engineer / Corrosion Engineer
Pipeline Integrity Manager or Asset Integrity Lead

Lateral Moves:

NDT Specialist / ASNT Level II or III
Quality Assurance / Quality Control Inspector
Health, Safety & Environmental (HSE) Specialist

Core Responsibilities

Primary Functions

Conduct scheduled and unscheduled field inspections of pipelines, storage tanks, meter stations and associated above-ground and below-ground assets, following approved inspection plans and ensuring all activities comply with company procedures and regulatory requirements.
Perform and verify non-destructive testing (NDT) techniques including ultrasonic thickness (UT), magnetic particle (MT), liquid penetrant (PT), visual inspection (VT), radiographic testing (RT) coordination, and guided wave testing, documenting results and anomalies accurately.
Execute corrosion monitoring tasks such as coupon/ER probe surveys, close interval potential surveys (CIPS), rectifier surveys, and soil sampling to assess corrosion mechanisms and recommend mitigation.
Operate and interpret inline inspection (ILI) tool reports and support tool selection, launch/receive logistics, and field validation of suspected anomalies with dig verification and defect characterization.
Measure and record pipe/tank wall thickness, weld conditions, coating integrity and other measurable indicators of asset health using calibrated portable instruments and field measurement techniques.
Prepare detailed inspection reports, deficiency notices and repair recommendations including photos, GPS coordinates, tag numbers, and severity assessments for use by integrity engineering and maintenance planning.
Plan and supervise field digs and maintenance interventions to excavate, expose, assess and (where applicable) repair pipeline defects in coordination with operations, construction and environmental teams.
Review and apply relevant codes, standards and regulations (API, ASME, ASTM, AWS, PHMSA, DOT) to inspection findings and ensure corrective actions meet regulatory obligations and industry best practices.
Identify pipeline threats (external corrosion, internal corrosion, mechanical damage, SCC, third-party interference) and apply risk-based integrity prioritization methods to support inspection frequency decisions.
Conduct root-cause analysis of failures, leaks or anomalies observed in the field, working with engineering to identify permanent corrective actions and preventive measures.
Monitor, document and enforce permit-to-work, lockout/tagout, hot work and confined space entry requirements during inspection and repair activities to ensure personnel safety and regulatory compliance.
Maintain and calibrate inspection and NDT equipment, ensure traceability of calibration records and report any equipment failures immediately to the maintenance lead.
Coordinate with landowners, stakeholders and right-of-way personnel to gain site access, document site conditions and minimize environmental and community impact during inspection and repair operations.
Support integrity data management by uploading field inspection results into the integrity management system (IMS), CMMS or GIS platforms in timely and standardized formats to maintain a single source of truth for asset condition.
Assist in the development and updating of asset integrity plans, inspection procedures, and maintenance work packs, providing field perspective to ensure practical, safe and effective inspection approaches.
Lead or participate in post-inspection review meetings, providing clear and concise briefings to integrity engineers, operations managers and senior leadership on findings, risks and recommended actions.
Perform weld inspection including visual weld acceptance, dimensional checks and verification of weld procedure specifications (WPS) and welder qualification records, escalating nonconforming welds.
Identify and verify coating defects, mechanical damage and cathodic protection issues, and recommend immediate mitigations such as temporary repairs, shielding or re-coating before permanent remediation.
Support hydrostatic testing, pressure testing and leak detection operations by providing inspection oversight, holding test boundaries and documenting test acceptance criteria and anomalies.
Maintain up-to-date knowledge of industry trends, new inspection technologies (robotics, acoustic emission, phased array UT), and regulatory changes to continuously improve inspection programs and techniques.
Mentor junior inspectors and NDT technicians in field techniques, safety practices and company inspection standards, fostering a culture of quality and continuous improvement.
Escalate urgent safety or integrity issues to the operations control center and integrity management team, and participate in emergency response and incident investigation when required.
Ensure proper chain-of-custody and evidence preservation for any failure analysis or incident investigation, coordinating with laboratory services for metallurgical or chemical analysis as needed.
Verify contractor performance and compliance when external inspection or dig contractors are used, reviewing deliverables, permits, and method statements to confirm adherence to specifications.

Secondary Functions

Support integrity program analytics by providing accurate field data for trending, KPI development and long-term asset risk forecasting.
Participate in cross-functional integrity reviews and audits, contributing field-level insights to support continuous improvement of procedures and programs.
Assist engineering teams with sample collection, tagging and shipment for laboratory corrosion or metallurgical testing, ensuring correct documentation and chain-of-custody.
Provide input to budget planning by estimating man-hours, equipment needs and materials for scheduled inspection and remediation projects.
Help develop and deliver training modules for new inspectors on company inspection standards, safety protocols and reporting systems.
Maintain and update inspection route plans and site access lists to optimize field efficiency and reduce mobilization time.
Participate in contractor pre-qualification and supplier assessments for inspection and repair service providers.
Review procurement requests for inspection materials and specialized NDT services, ensuring technical specifications meet inspection objectives.
Support permit-to-work coordinators with hazard assessments and control measures during complex excavation or repair activities.
Contribute to the organization's continuous improvement initiatives by recommending procedural changes and technology adoption to enhance field inspection accuracy and safety.

Required Skills & Competencies

Hard Skills (Technical)

API 1169 pipeline inspector knowledge and/or certification familiarity with pipeline construction and inspection standards.
Proficient in non-destructive testing methods (UT, MT, PT, RT, VT) with hands-on experience using ultrasonic thickness gauges, MPI yokes, penetrant kits and radiography coordination.
Experience interpreting inline inspection (ILI) reports, geometry and metal-loss data and correlating tool data to physical field anomalies.
Strong understanding of corrosion mechanisms (external corrosion, internal corrosion, MIC, SCC) and corrosion control methods including cathodic protection and coatings.
Competence with field data systems: GIS, CMMS (Maximo, SAP), integrity management software and digital mobile data collection tools.
Ability to read and interpret engineering drawings, P&IDs, weld maps, isometrics and technical specifications.
Familiarity with regulatory frameworks: PHMSA/DOT, EPA, local/state pipeline safety codes and industry standards (API, ASME, ASTM).
Experience conducting excavation/dig programs, defect excavation criteria, and coordinating remediation welding and repair activities.
Skilled in using measurement and verification equipment: calipers, thickness gauges, torque wrenches, NDT instrumentation and GPS mapping devices.
Basic understanding of welding inspection criteria, weld symbols, common welding defects and qualifications (AWS).
Proficiency with Microsoft Office suite, inspection report generation, and electronic photo documentation best practices.
Experience with leak detection methods, pressure testing oversight, and test documentation for hydrostatic and pneumatic tests.
Knowledge of safe work practices including confined space entry, hot work, LOTO, and permit-to-work systems.
Certification awareness: ASNT Level II/III, NACE Coating Inspector / Cathodic Protection certifications, OSHA 10/30, H2S, First Aid/CPR.

Soft Skills

Strong attention to detail with ability to produce clear, well-structured inspection reports that support decision-making by engineers and operations.
Excellent verbal communication skills for coordinating with field crews, stakeholders and regulators and for delivering concise safety briefings.
Sound problem-solving and analytical thinking to assess complex integrity issues and recommend practical remedial actions.
Ability to work independently in remote field environments while maintaining accountability and accurate record keeping.
Team collaboration and stakeholder management skills to coordinate multi-discipline activities and drive corrective actions to completion.
Time management and organizational ability to prioritize inspections, manage multiple sites and meet reporting deadlines.
Adaptability and resilience in dynamic field conditions including adverse weather, schedule changes and emergency response scenarios.
Ethical judgement and compliance mindset to ensure inspections are unbiased, traceable and compliant with all regulatory and company standards.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with relevant technical trade school certification or vocational training in NDT, welding or mechanical inspection.

Preferred Education:

Associate or Bachelor's degree in Mechanical Engineering, Materials Science, Metallurgy, Petroleum Engineering, or a related technical discipline.

Relevant Fields of Study:

Mechanical Engineering
Materials Science / Metallurgy
Petroleum or Chemical Engineering
NDT Technology / Welding Inspection
Industrial Safety or Inspection Technology

Experience Requirements

Typical Experience Range:

3 to 7 years of progressively responsible field inspection or NDT experience in pipelines, oil & gas, utilities, or heavy industrial environments.

Preferred:

5+ years of pipeline integrity inspection experience with hands-on NDT and ILI correlation, plus one or more industry certifications (API 1169, ASNT, NACE).
Demonstrated experience with regulatory compliance (PHMSA/DOT) and implementing integrity remediation projects.