Refinery Industry Solutions

Integrity and safety engineering for refineries managing ageing equipment, high hydrocarbon inventory & complex protection layer reliability.

INDUSTRIES NAVIGATION

Moving your facility from reactive maintenance to Predictive Integrity using AI-driven data modeling.

Why Refineries Need Engineering Strategy?

Refinery risk isn’t a single design-basis event, it’s the compounding effect of equipment degradation on protection layer reliability over time. As plants age past their original design assumptions, safeguards that once performed as intended can quietly drift from that basis. Pure Integrity helps refineries close that gap before it surfaces as a compliance finding or an incident.

Our Approach for Refinery

Risk Profile

High hydrocarbon inventory across densely interconnected process units (crude, conversion, treating), with ageing static and rotating equipment often operating past original design assumptions.

Risk isn’t just process deviation, it’s the compounding effect of equipment degradation on protection layer reliability over time.

Standards Applied

IEC 61511 (SIS lifecycle, SIL determination/verification), RCM-driven maintenance strategy frameworks, and Risk Based Inspection (RBI), treated as part of the safety lifecycle rather than a separate exercise. Asset reliability directly affects whether safeguards perform as claimed.

Typical Client Outcome

Experienced personnel lead studies that help ageing refineries demonstrate ALARP, execute fit-for-purpose maintenance strategies & maintain high plant uptime.

Common Challenges Across Industries

Services

Pure Integrity provides a full range of process safety, functional safety & asset integrity services to support refineries at every stage of the plant lifecycle.

HAZOP / HAZID Consultant

Identifying process hazards and operability issues before they become incidents.

Explore Service

SIL Determination & Verification

Establishing and verifying safety integrity levels for critical safety instrumented functions.

Explore Service

Risk Based Inspection (RBI)

Prioritising inspection effort based on risk, criticality & failure consequence.

Explore Service

Asset Integrity

Supporting safe, reliable, and fit-for-service assets throughout their operating life.

Explore Service

Functional Safety

Ensuring safety instrumented systems perform reliably across their full lifecycle.

Explore Service

CHALLENGES WE SOLVE FOR REFINERY

Disconnected Hazard Studies and Maintenance Strategy

HAZOP and SIL identify what protects against a hazard, RCM confirms that protection still works when needed. We bridge both deriving protection layer credit and maintenance tasks from one shared hazard basis, not two separate teams.

Incomplete or Unreliable Asset Registers

Decades of modifications leave older assets with gaps and incorrect tags. We rebuild the register into a trustworthy baseline, since credible RCM or SIL verification isn't possible without one.

Alarm Rationalization on a Live, Complex Refinery DCS

Decades of accumulated alarms with no rationalization baseline is common. We develop an Alarm Management Philosophy and run the rationalization exercise, cutting nuisance alarms while keeping critical ones actionable.

MoC Gaps Eroding the Safety Basis Over Time

Years of tie-ins and revamps can quietly invalidate the original hazard basis if changes aren't formally assessed. We audit the MoC trail against the existing hazard and SIL basis, closing the gap between what was assessed and what's actually installed today.

OUR METHODOLOGY

Johan Andak

Managing Director
Pure Integrity Sdn Bhd

Johan Andak is a process safety and operations specialist with decades of experience in the oil and gas, petrochemical, and energy sectors. As Managing Director of Pure Integrity, he provides strategic and technical leadership in process safety, functional safety, and risk assessment, supporting major projects across Southeast Asia, the North Sea, West Africa, Brazil, and Australasia.

Education & Certificate

Who We Work With

We have worked closely with many local and multi-national companies in Malaysia as well as overseas to fulfill their specific needs. Through close collaboration we have helped clients deliver safer, more reliable, and cost effective operations.