Mechanical Integrity Expert Witnesses

Bridgeton, New Jersey

Engineering, Oil and Gas - Corrosion, Mechanical Integrity, Materials Engineering, Corrosion Engineering, Root Cause Analysis, Industrial Equipment, Failure Analysis, Inspection Adequacy, Risk-Based Inspection Expert, RBI Expert Witness, Piping, Pressure Vessel, Tank, Pipeline, Refinery, Chemical Plant, Coating, Material Selection

Dr. Sean Brossia is a corrosion, materials, mechanical integrity, reliability, and industrial equipment failure expert with more than 30 years of experience in chemical, refining, pharmaceutical, paper, pipeline, manufacturing, and industrial facilities. He provides expert witness and litigation support through Vulcan Integrity for matters involving corrosion damage, materials degradation, inspection adequacy, risk-based inspection, mechanical integrity, maintenance and reliability practices, material selection, and equipment failure causation. Dr. Brossia has experience with piping, pressure vessels, tanks, heat exchangers, boilers, cooling water systems, pipelines, coatings, linings, stainless steels, specialty alloys, polymers, gaskets, glass-lined equipment, PTFE-lined systems, corrosion sensors, and corrosion monitoring technologies. He evaluates damage mechanisms including pitting, general corrosion, localized corrosion, erosion-corrosion, corrosion under insulation, microbio...

Horseshoe Bay, Texas

Chemical Engineering - Process Safety, Chemical Process Safety, Governance, Outsource Manufacturing, Leadership, Fires, Explosions, Management System, Chemical Exposure, Acid Exposure, Safe Work Practices, Permits, Toxic Chemical Release, Chemistry, Chemicals, Reactive Chemicals, Reactivity, Toxicity, Mechanical Integrity, Safeguards

• I am a recognized thought leader in process safety — co-author of two CCPS publications that define the standard of care in process safety litigation and governance: Process Safety: Leadership from the Boardroom to the Front Line (Wiley/CCPS, 2019) and Guidelines for Process Safety in Outsourced Manufacturing, 2nd Edition (CCPS, 2026). When opposing counsel challenges the standard of care, my opinions carry the weight of the CCPS frameworks I helped author. • My standard-of-care authority is grounded in 44 years of hands-on experience — 21 of them in direct operational roles including Plant Manager, Production Leader, and Site Director — running the chemical facilities where process safety is won or lost at the front line. That operational foundation distinguishes my analysis from purely academic or staff-function experts. • At Dow Chemical (Fortune 50), across two positions I led the corporate initiative that achieved a cumulative 90% reduction in Tier 1 incidents over ten year...