Executive Summary
Oil and gas equipment manufacturers and operators face one of the most demanding TIC environments in any industry. A single wellhead assembly may require pressure containment testing to API 6A, material qualification for sour service per NACE MR0175/ISO 15156, factory acceptance testing witnessed by the end client’s inspector, and explosion protection certification to ATEX Directive 2014/34/EU or IECEx — each governed by different standards bodies, notified bodies, and client-specific requirements that layer on top of the base codes.
TIC planning for oil and gas equipment is uniquely complex: designs span wellhead and christmas tree assemblies, subsea valves, downhole tools, surface processing equipment, and rotating machinery — each with distinct pressure ratings, material grades, service classifications, and environmental envelopes. A single valve may require hydrostatic shell testing, hydrostatic seat testing, gas backseat testing, functional testing, and cryogenic testing depending on the specification. Material qualification alone involves impact testing at multiple temperatures, hardness surveys across weld zones, SSC and HIC testing for sour environments, and positive material identification for every pressure-retaining component.
This module deploys the Agentic TIC Platform for oil and gas equipment — automatically producing comprehensive, traceable, audit-ready inspection and test plans by synthesizing API, ASME, NACE, and ATEX/IECEx standards with equipment specifications, material certifications, and historical nonconformance data. The system generates complete TIC programs from standards ingestion through test execution planning, witness point scheduling, and certification evidence assembly.
Target Users & Personas
Persona | Role | Primary Needs |
QA/QC Manager | Owns the quality plan and TIC program for equipment manufacturing | Automated ITP generation, witness point scheduling, nonconformance tracking, certification package assembly |
Materials Engineer | Responsible for material selection and qualification | Sour service qualification test plans, MTR verification checklists, welding procedure qualification, corrosion testing programs |
Third-Party Inspector | Performs independent inspection per client or regulatory mandate | Structured inspection checklists, hold/witness point definitions, evidence capture requirements, finding classification guidance |
HSE / Compliance Manager | Ensures explosion protection and safety compliance | ATEX/IECEx documentation packages, zone classification verification, Ex equipment inspection checklists |
Project / Program Manager | Drives manufacturing schedule and client delivery | Test milestone tracking, inspector availability coordination, certificate lead-time visibility, change impact assessment |
Client Representative | Represents the end operator during FAT and documentation review | Clear hold/witness point definitions, real-time inspection status, deviation disposition transparency, final dossier completeness |
Core Capabilities
1. Pressure Containment Test Program Generation
The platform ingests applicable pressure equipment standards — API 6A, API 6D, API 17D, ASME BPVC Section VIII, and client-specific purchase order requirements — and generates complete hydrostatic and gas test programs:
Test Pressure Calculation & Verification: Automatically computes required test pressures from rated working pressure, material grade, and temperature class per API 6A Table 4/5 or ASME VIII UG-99 — including hold times, acceptance criteria, and test medium requirements for each pressure rating and product specification level (PSL 1–4)
Multi-Stage Test Sequencing: Generates sequenced test programs covering hydrostatic shell test, hydrostatic seat test, gas seat test, backseat test, and functional test — with correct ordering, pressure levels, hold durations, and acceptance criteria per the applicable standard and valve type (gate, ball, check, choke)
Test Equipment & Calibration Requirements: Specifies required test equipment (pressure transducers, chart recorders, dead-weight testers), calibration requirements, and measurement uncertainty budgets — ensuring NIST-traceable measurement chains per API 6A Annex F
Client Overlay Requirements: When purchase orders specify requirements beyond the base code — extended hold times, additional test points, cold hydro at minimum design temperature, or specific chart recorder documentation — the Planner overlays these on the base test program and flags any conflicts with the standard
2. Sour Service Material Qualification (NACE MR0175 / ISO 15156)
Material qualification for sour (H₂S-containing) service environments requires a rigorous testing and documentation program that the platform automates end to end:
Material Selection Verification: The Standards Interpreter ingests ISO 15156 Parts 1–3 and cross-references against the equipment’s specified materials — verifying that each pressure-retaining component’s material grade, heat treatment condition, and hardness limits comply with the applicable table and environmental severity level (SSC Region 1–3)
SSC & HIC Test Plan Generation: Generates sulfide stress cracking (SSC) test plans per NACE TM0177 (Method A tensile, Method B bent beam, Method D DCB) and hydrogen-induced cracking (HIC) test plans per NACE TM0284 — with specimen orientation, test solution chemistry (Solution A vs. B), loading conditions, and acceptance criteria
Hardness Survey Programs: Produces hardness survey plans for base metal, weld metal, and heat-affected zones per NACE MR0175 requirements — including traverse patterns, indent spacing, maximum allowable hardness by material and product form, and documentation requirements
Weld Procedure Qualification Integration: Links material qualification to welding procedure specifications (WPS) and procedure qualification records (PQR) — ensuring that weld consumables, preheat/interpass temperatures, and PWHT conditions comply with NACE requirements and that PQR mechanical test results meet sour service thresholds
3. Factory Acceptance Testing (FAT) Program Generation
Factory acceptance testing for oil and gas equipment involves coordinated execution of pressure, functional, dimensional, NDE, and documentation checks — typically witnessed by client inspectors and third-party agencies:
Inspection & Test Plan (ITP) Generation: Produces complete ITPs with hold points (H), witness points (W), monitor points (M), and review points (R) for every manufacturing and testing milestone — from material receipt through final painting and packing — calibrated to PSL level and client requirements
NDE Program Planning: Generates non-destructive examination programs: radiographic testing (RT) per ASME V Article 2, ultrasonic testing (UT) per ASME V Article 5, magnetic particle testing (MT), and liquid penetrant testing (PT) — with acceptance criteria per ASME VIII or API 6A, coverage requirements, and NDE operator qualification needs
Dimensional & Functional Verification: Produces dimensional inspection checklists against manufacturing drawings and API/ASME tolerances, plus functional test procedures for stem travel, torque-to-operate, backseat engagement, and emergency shutdown actuation
Manufacturing Record Book (MRB) Assembly: The Certifier agent assembles the complete manufacturing record book: material certificates (MTR/3.1/3.2), heat treatment records, NDE reports, pressure test charts, dimensional records, coating reports, and final release certificate — with traceability from every document to its ITP requirement
4. Explosion Protection Certification (ATEX / IECEx)
Equipment destined for hazardous areas must be certified under ATEX Directive 2014/34/EU, IECEx, or both — requiring type examination, quality system assessment, and ongoing production surveillance:
Ex Classification & Protection Concept Mapping: The Standards Interpreter ingests IEC 60079 series standards and maps the equipment’s protection concept (Ex d flameproof, Ex e increased safety, Ex p pressurized, Ex n non-sparking) to the applicable testing and certification requirements — including temperature class, equipment group, and EPL
Type Examination Test Plan Generation: Generates complete test programs for Notified Body (ATEX) or ExTL (IECEx) submission: enclosure strength testing (IEC 60079-1), thermal testing, impact testing, ingress protection (IP), and internal ignition testing — with specimen requirements, test configurations, and acceptance criteria
Quality System (QAR) Documentation: Produces documentation packages for ATEX Quality Assurance Notification (Module D/E) or IECEx QAR: manufacturing process controls, routine test procedures, component traceability requirements, and production inspection checklists
Installation & Periodic Inspection Plans: Generates Ex equipment installation inspection checklists per IEC 60079-14 and periodic inspection programs per IEC 60079-17 — covering cable entries, enclosure integrity, earthing continuity, temperature monitoring, and documentation verification
Data Architecture & Sources
Data Layer | Sources | Update Frequency |
Standards & Codes | API 6A/6D/17D, ASME BPVC (V, VIII, IX), NACE MR0175/ISO 15156, IEC 60079 series, ATEX Directive, EN 13463, client-specific purchase order specs | Event-driven (standard revision, addenda); annual (code edition cycles) |
Equipment Design Data | General arrangement drawings, material specifications, pressure/temperature ratings, bill of materials, welding procedure specifications (WPS/PQR) | Per-project at order entry; updated on engineering change orders |
Material Certifications | Mill test reports (EN 10204 3.1/3.2), heat treatment records, PMI results, corrosion test certificates (SSC/HIC), hardness survey records | Per-material lot; ingested at goods receipt; updated on re-test |
Historical TIC Records | Prior ITPs, pressure test charts, NDE reports, nonconformance records, client deviation requests, corrective action logs from previous orders | Ingested at program kickoff; updated at manufacturing milestones |
Regulatory & Certification | ATEX certificates of conformity, IECEx certificates, Notified Body audit findings, QAR documentation, production surveillance records | Event-driven (certificate issuance, audit finding); annual (surveillance) |
Inspector & Witness Data | Client inspection requirements, third-party agency scopes, inspector qualification records, witness point release logs, punch list items | Per-project; updated at each hold/witness point release |
Multi-Agent Architecture
Agent | Responsibility | Triggers |
Standards Interpreter | Ingests and decomposes API, ASME, NACE, and IEC 60079 standards into structured, machine-readable requirements. Maps code clauses to testable criteria, acceptance thresholds, and evidence obligations. Resolves conflicts between base code and client purchase order overlays. | New standard revision; project kickoff; purchase order receipt with special requirements |
Planner | Generates complete TIC programs: pressure test procedures with calculated test pressures, material qualification test plans, ITP with hold/witness/monitor points, NDE programs, and ATEX type examination test plans. Optimizes sequencing based on manufacturing flow and inspector availability. | Project kickoff; engineering change orders; PSL or service classification change |
Inspector | Orchestrates inspection execution against the ITP. Processes evidence — pressure test charts, NDE films/reports, dimensional records, hardness readings — against acceptance criteria. Classifies findings by severity and generates structured nonconformance records with evidence links. | Each ITP hold/witness point; continuous during FAT campaign |
Analyst | Cross-references historical TIC data to surface patterns: recurring NDE indications by weld joint type, pressure test failure modes by valve size/rating, material hardness exceedances by supplier and heat — informing risk-based inspection intensity and supplier surveillance priorities. | Invoked at program generation; on-demand for root cause investigation |
Remediator | Manages the nonconformance lifecycle: drafts disposition recommendations (use-as-is, repair, reject), tracks corrective action through verification closure, manages client concession requests, and escalates overdue items with evidence. | NCR creation; corrective action due dates; client concession request |
Certifier | Assembles complete certification packages: manufacturing record books (MRB), pressure test certificates, material compliance dossiers, ATEX/IECEx technical files, and certificates of conformity — with traceability from every document to its ITP requirement and code clause. | Manufacturing completion; pre-shipment; ATEX/IECEx submission milestones |
Example Workflow: API 6A PSL-3 Sour Service Gate Valve with ATEX Certification
The following illustrates how the system handles a complete TIC program generation for a high-pressure sour service gate valve requiring simultaneous API 6A, NACE MR0175, and ATEX Ex d certification:
Step 1 — Standards Ingestion & Requirements Decomposition The Standards Interpreter ingests API 6A (PSL 3, PR2, Material Class EE), NACE MR0175 (SSC Region 1 for 5% H₂S at 65°C), and ATEX (Group II, Category 2, Ex d IIB T4). It decomposes 1,247 individual requirements across the three standards, maps each to a testable criterion, and identifies 23 client purchase order overlays that exceed the base code (extended hold times, additional NDE coverage, cold hydro at -29°C). | Step 4 — ITP & FAT Program Generation The Planner produces the complete ITP: 94 inspection points (12 hold, 18 witness, 31 monitor, 33 review) spanning material receipt through final packing. It generates pressure test procedures with calculated test pressures (shell: 1.5x RWP = 22,500 PSI, seat: 1.1x RWP), NDE programs (100% RT on pressure welds, 100% MT on accessible surfaces), and dimensional inspection checklists against 47 critical dimensions. |
Step 2 — Material Qualification Planning The Planner generates the complete sour service qualification program: SSC testing per NACE TM0177 Method A for all pressure-retaining components, HIC testing per TM0284 for plate material, hardness surveys (base metal, weld metal, HAZ) with HRC 22 max per NACE, and PMI requirements for every pressure-containing part. It cross-references 14 WPS/PQR combinations against NACE hardness limits and flags 2 PQRs requiring supplemental impact testing. | Step 5 — ATEX Certification Planning The Planner generates the Ex d flameproof enclosure test program: hydrostatic strength test (1.5x reference pressure), impact test at -20°C per IEC 60079-0, flamepath dimensional verification, and internal ignition test with representative gas mixtures per IEC 60079-1. It also produces the QAR routine test checklist and component traceability requirements for the Notified Body submission. |
Step 3 — Historical Pattern Analysis The Analyst retrieves TIC records from 38 prior orders of the same valve family. It identifies that UT rejection rates on body-to-bonnet welds increased 40% when a specific forging supplier changed sub-tier sources in Q3 2025, and that 3 prior orders had pressure test failures traced to inadequate PWHT soak time documentation. These patterns feed into elevated inspection intensity on the current ITP. | Step 6 — Certification Evidence Assembly The Certifier assembles the complete deliverable package: manufacturing record book (MRB) with 247 linked documents, NACE compliance dossier with full material traceability, ATEX technical file with type examination cross-references, and certificate of conformity with clause-by-clause compliance matrix. Total time from order receipt to TIC-ready program: under 5 hours vs. 4–6 weeks manually. |
Key Differentiators vs. Manual TIC Planning
Differentiator | Impact |
Agentic, not template-driven | Reasons across the full code basis — API, ASME, NACE, ATEX/IECEx, and client PO overlays simultaneously — resolving conflicts and generating programs calibrated to the specific equipment, not generic templates adapted manually for each order |
Multi-code synthesis | A single valve may require API 6A pressure testing, NACE MR0175 material qualification, ASME IX welding qualification, and ATEX certification. The platform generates a unified TIC program that addresses all four code regimes with correct sequencing and no coverage gaps |
Client overlay resolution | When purchase orders specify requirements beyond the base code, the system overlays them on the standard program, flags conflicts, and produces a reconciled test plan that satisfies both the code and the client — eliminating the manual cross-referencing that causes missed requirements |
Historical pattern intelligence | Cross-references prior orders to surface recurring NDE rejection patterns, pressure test failure modes, and supplier-specific material issues — informing risk-based inspection intensity rather than applying uniform coverage regardless of risk |
Inspector-ready traceability | Every test procedure, acceptance criterion, and inspection checkpoint links to its source code clause and PO requirement — producing documentation that third-party inspectors and client representatives can verify against the standard in real time |
Certification package assembly | Produces complete MRBs, NACE dossiers, and ATEX technical files with full clause-to-evidence traceability — eliminating the weeks of manual document compilation that typically gate equipment shipment |