Tru-Fit inspection results can be used as inputs to the connector condition index (CCI) framework, enabling connector populations to be analysed, compared and prioritised based on measured assembly condition.

The Challenge

Connector failures often go unnoticed until loss of containment occurs. Traditional inspection methods provide limited visibility and often result in unnecessary system opening and reactive maintenance, creating operational risk, unplanned downtime, and avoidable intervention. These unplanned events carry significant safety and financial consequences, including lost production, emergency repairs, regulatory penalties, and extended shutdown costs.

HSE guidance confirms that relevant good practice is the foundational requirement for any ALARP demonstration. For small-bore tubing integrity, this means using inspection methods capable of reliably identifying assembly-related degradation.

Independent comparative studies, including published academic evaluations, have shown that conventional visual and gauge-based inspection methods have limited probability of detection (PoD) for certain connector assembly conditions. Within these studies, Tru-Fit demonstrated significantly higher detection capability under the evaluated conditions.

Many small-bore tubing (SBT) systems perform safety-critical functions. HSE has published detailed guidance on inspection and non-destructive testing (NDT), recognising that flaws in critical components can compromise system integrity and increase the likelihood of failure. The guidance explains that inspection is often the only practical means of obtaining information about the condition or ‘health’ of process plant and that inappropriate inspection can give a false impression of plant integrity and safety.

HSE also recognises that the required inspection performance should reflect the criticality of the component being inspected. In its published inspection case studies, HSE states:

“A probability of detection of only 50% may be acceptable for a regularly applied, non-critical inspection whilst for a highly critical inspection the probability of detection would need to be up near 95%.”

Independent studies have reported probability of detection (PoD) values of approximately 30% for gap gauges, 46% for close visual inspection, and 99% for Tru-Fit when assessing compression fitting assembly conditions.

As a result, Tru-Fit provides inspection evidence that is better aligned with recognised good practice for identifying connector assembly conditions and supporting ALARP demonstrations within integrity management programmes.

Tru-Fit does not replace ALARP assessments, risk evaluations or engineering judgement. It provides higher-quality inspection data to support those decision-making processes.

Further HSE guidance

HSE Hazardous Installations Directorate (HID) has also published guidance covering ALARP demonstrations, inspection capability and the introduction of new technology. These documents are provided below for reference.

The Tru-Fit Methodology addresses this problem by making assembly condition measurable, reliable, and actionable. By prioritising maintenance based on actual connector risk, it helps organisations reduce operational expenditure, avoid costly failures, and optimise resource allocation, delivering both safety and financial benefits across the asset lifecycle.  Tru-Fit provides strong, verifiable evidence that the inspection element of the SBT integrity management system meets relevant good practice, which is a foundational component of any ALARP demonstration.

Can you demonstrate your existing SBT inspection method provides an effective barrier?