Engineering Consulting

At Horsehead Consulting, we provide a wide range of engineering consulting services to operators of oil and gas assets. Our priorities focus on risk reduction, integrity maintenance, and extending service life of mainline, facility, and terminal assets. Our engineers are experienced in risk assessment, integrity management, and future planning.


Our risk assessment program insures compliance with relevant safety, health, environmental protection, and quality standards. Risk assessment aims at improving the security of supply, maintenance of safety operations, and risk reduction. The key steps in our risk assessment program include:

  • Client system segmentation
  • Threat and hazard identification
  • Threat succeptibility assessment
  • Consequence analysis
  • Risk result presentation per client-specific requirements
  • Prioritization of future integrity actions


Operators spend a disproportionate amount of time and resources on reactive management rather than on long-term corrosion control and management. Impactful corrosion control and management can insure integrity, while also minimizing costs. Horsehead Consulting corrosion experts can provide a range of consulting exercises, including:

  • Corrosion risk-assessment and strategy
  • Corrosion control, mitigation, and prevention
  • Corrosion modeling and growth mapping
  • Optimized inhibition and cleaning
  • Root cause, failure analysis, and mitigation action plans
  • Aging asset life extension
  • Cathodic protection and coatings strategy


Our integrity assessment team performs a series of integrity assessments, including:

  • Feature distributions and identifying activity hot spots
  • Characterization and diagnosis of reported corrosion
  • Consideration of High Consequence Areas (HCAs) for prioritization
  • Assessment of metal loss features in accordance with applicable codes
  • Assessment of other features (e.g. dents) reported by inspection
  • Identification and prioritization of features requiring repair
  • Visualize assessment results utilizing risk matrix


A PIMS relies on a number of core elements such as people, procedures, and methodologies, as well as data and software. To be impactful, a PIMS must:

  • Clearly define Key Performance Indicators (KPIs)
  • Be supported my an impactful staff organizational structure and training program
  • Have access to accurate and comprehensive pipeline data
  • Be aligned with existing operational and maintenance procedures and practices
  • Be supported by appropriate software enabling regular review pipeline risks and outputs that fit client metric system
  • Be regularly updated to incorporate changes such as regulatory updates, technological improvements, and modified pipeline threats


Procedures define the interaction between the Pipeline Integrity Management System components. The goal is to insure that the objectives are archived and that every tactic is performed and controlled, validated, and contributes to integrity.

Client-specific processes are developed and implemented by our experienced team of engineers, taking into account the regulations of our clients and federal/state government agencies. Our team makes decisions based on potential risks, as well as audits and evaluation.


Our informed team of experts assesses active corrosion areas and identifies causes, quantities, and rates of corrosion activity on oil and gas pipelines. These experts have a strong understanding of the causes of corrosion. They analyze the corrosion process using state-of-the-art methodologies and evaluate the credibility of corrosion rates. This corrosion evaluation provides a detailed view of how corrosion has developed over time and significantly increases operators’ confidence in the future pipeline integrity.