Published and Presented at Reputable Venues

Our consultants provide thought leadership in many areas of asset integrity and asset performance management. From developing the base resource document for what today has become API 580 to writing corporate risk policies for major refiners and petrochemical and chemical manufacturers, our consultants continue to produce hundreds of successful and sustainable risk based inspection programs. We have also taken the time to work with Owners to co-author many publications summarizing these successes. We welcome you to take a moment to review some of these publications that were presented at reputable venues such as NPRA, NACE, AIChe, CCPS and API as well as user group forums for Meridium and Lloyd's Register Capstone to mention a few.

Ensuring Lower Life-Cycle Costs by Integrating Maintenance Execution and Reliability Management Work Processes

Ensuring Lower Life-Cycle Costs by Integrating Maintenance Execution and Reliability Management Work Processes

This presentation demonstrates how integrating maintenance execution and reliability work processes is essential to improving asset conditions and reducing their life-cycle costs.
  • By David Rosenthal, PE
  • - Maintenance Technology - Maintenance and Reliability Conference, 2015

Time to Value - Asset Integrity Management Delivered, Confidently, Comprehensively and Quickly. An AOC & Intergraph RBI Solution

Time to Value - Asset Integrity Management Delivered, Confidently, Comprehensively and Quickly. An AOC & Intergraph RBI Solution

Delivering knowledge based asset files from the true sources of data - confidently, accurately, electronically, and in half the time.
  • By Edward J. Mullings

The presentation discusses how Fusion allows our engineers to more quickly and efficiently extract accurate and current, critical equipment and piping data whether electronic or paper based that can readily migrate into the plethora of technologies such as Meridium, PCMS, APIRBI, SAP PM, Ultrapipe, Capstone RBMI, ACET, or Credo as well as facilitate expedite reconciling piping circuits, line numbers, and TML information from a variety of data sources, including isometric drawings, circuitized P&IDs, IDMS, and RBI databases.

  • - Intergraph Corporation, 11/11/2014

Implementing RBI in Remote Locations

Implementing RBI in Remote Locations

The importance of understanding risk and the significant value attainable through the implementation of risk based inspection (RBI)
  • By Paul Sheriff and Leon Johnson

The project expedited developing Cristal's Process Safety Management (PSM) standards and being able to meet the more stringent local requirements from the H&SE. The project developed Cristal's asset management requirements for Mechanical Integrity as outlined in the five year PSM plan submitted to HSE. Cristal were able to reduce unexpected failures on critical equipment and demonstrate the significant value attainable through the implementation of Risk Based Inspection. Cristal has continued establishing its RBI program at other Cristal sites.

  • - Meridium User Conference, 1/28/2014

Maintenance Contractor/Owner Partnership: Increased Uptime and Lower Maintenance Costs

Maintenance Contractor/Owner Partnership: Increased Uptime and Lower Maintenance Costs

This paper demonstrates the success of owner partnerships with their Maintenance Contractor aimed at improving owner uptime, reducing maintenance costs, and minimizing the consequences of failure.
  • By David Rosenthal, PE
  • - Society for Maintenance & Reliability Professionals, Maintenance & Reliability Symposium, 8/15/2013

Corporate Reliability Programs - Are They There To Help?

Corporate Reliability Programs - Are They There To Help?

Reliability is the probability that the equipment will perform its intended function when required. This paper examines the realities of improving reliability to have predictable supply chain processes and how this reality must feed the planning process in lieu of assumptions based on very historical and less than optimum performance.
  • By David Rosenthal, PE
  • - Society for Maintenance & Reliability Professionals, 10/14/2013

An Update on Risk Based Inspection: Bringing Focus on External Corrosion Under Insulation, Stress Corrosion Cracking And Other Damage Mechanisms - Reliability and Maintenance (RMC-12-46)

An Update on Risk Based Inspection: Bringing Focus on External Corrosion Under Insulation, Stress Corrosion Cracking And Other Damage Mechanisms - Reliability and Maintenance (RMC-12-46)

Using RISK as a basis for maintenance planning
  • By Joel Presley, Tim Munsterman, and Ed Mullings

Using RISK as a basis for maintenance planning - Since its introduction over fifteen years ago, the concepts of risk-based inspection (RBI) have been applied successfully in many plants around the world. Risk-based inspection is a systematic process for factoring risk into decisions concerning how, where, and when to inspect a process plant. RBI focuses inspection resources on the highest priority equipment to determine asset integrity. RBI cost effectively helps make process plants safer and more reliable.

  • - NPRA Reliability & Maintenance Conference & Exhibition, 5/22/2012

RBI Training Manual

RBI Training Manual

RBI Defined - Risk-Based Inspection (RBI) technology has revolutionized the process industry and its approach to managing the inspection of process plants. It is a unique technology that can provide improvements in safety and production while reducing costs.
  • By John Aller

"Overall Equipment Effectiveness" for the Process Industry Overall Equipment Effectiveness (OEE) was developed to measure individual equipment performance. It has been adapted for use with process performance, but there is a method that is specifically designed to measure performance and drive improvement for production processes: Asset Utilization (AU & OAU). Asset Utilization measures and enables you to manage all losses, quantifying them in a manner that shows the impact on overall production (as opposed to impact of certain equipment). This paper explains how the Asset Utilization approach can incorporate OEE, yielding a powerful and sustainable improvement tool that applies consistent principles across widely varied processes; this done while generating unprecedented clarity of manufacturing management information. In this paper we will cover the value proposition for productivity improvement in your organization; process complexity and the role of the process constraint; basic loss types; methods to gain clarity of loss reasons; effective categorization; workforce engagement; considerations for process yield and quality; and improvement work processes that bring business value.

  • - Materials Technology Institute, St. Louis, MO, 2012

Does Your Maintenance Contractor Care For Your Assets?

Does Your Maintenance Contractor Care For Your Assets?

What more can you do for me? To answer that question correctly, contractors need a broader perspective of asset care. This article shows why maintenance contractors are well positioned to leverage the owners maintenance execution workflow, eliminating defects, controlling bad actors and continually improving asset care work processes and procedures to improve the effectiveness of PM, PdM and CM tasks.
  • By David Rosenthal, PE
  • - Maintenance Technology, July, 2011

From Fitness for Service to a Reliability-Based Mechanical Integrity Program - A Journey from the Ashes to Sustained Reliability (RMC-10-30)

From Fitness for Service to a Reliability-Based Mechanical Integrity Program - A Journey from the Ashes to Sustained Reliability (RMC-10-30)

An upgrader is brought safely back into production a year ahead of expectations, avoiding an opportunity cost exceeding $300 million.
  • By Lenin Elorza

The fitness for service/salvage study was completed on the fractionator on January 28, 2005. As a result of the study, the Alberta Boiler Standards Administration (ABSA) allowed the repaired fractionator and upgrader to be brought back to full production a year earlier than expected. Following the study we began implementing a risk based inspection program based on the API 580 certified reliability based mechanical integrity (RBMI) technology and work processes.

  • - Reliability and Maintenance Conference, 5/25/2010

Integrity Operating Windows - Another Tool to Mitigate Risk

Integrity Operating Windows - Another Tool to Mitigate Risk

What are your reliability goals – NO SURPRISES and more! This presentation analyzes how to Integrity Operating Windows provides yet another tool for mitigating risk.
  • By David Mainwaring

What are your reliability goals – NO SURPRISES and more! This presentation analyzes how to Integrity Operating Windows provides yet another tool for:

  • Achieving and maintaining PSM, RMP, and EHS compliance
  • Managing risk, reducing leaks and the potential catastrophic releases
  • Maximizing equipment availability
  • Optimizing maintenance
  • Improving accuracy of damage predictions and correlate with actual experience
  • Providing early recognition of equipment risks due to process deviations
  • Improving timely feedback and assessment of changes to operations or maintenance
  • Identifying candidates for end of life evaluations
  • - Lloyd's Register Conference, 2010

Mechanical Integrity and Reliability: From Anticipating Failure Modes to Planning

Mechanical Integrity and Reliability: From Anticipating Failure Modes to Planning

A FMECA study reprioritized the inspection regime leading to a multimillion dollar savings in maintenance costs over a five year period.
  • By Ed Mullings

Located on the Grand Banks, offshore Newfoundland Canada, the Terra Nova FPSO, stands in 95 meters of water and must withstand the harsh 100-year storm environment and be disconnected to avoid colliding with large icebergs. This presentation evaluates how applying a FMECA study reprioritized the inspection regime for the directional propellers, including measuring bearing tolerances, bolting, sealing arrangements, operating conditions and lubricating fluid analysis leading to a multimillion dollar savings in maintenance costs over a five year period without affecting the reliability as required by the Register Rules and Regulations of Classification of Floating Offshore Installation at a Fixed location.

  • - Lloyd's Register Conference, 2010

Using RBI For Optimizing Turnarounds

Using RBI For Optimizing Turnarounds

Examine how data can be used to project risk across multiple T/A horizons allowing the turnaround planner to prioritize more effective inspections where needed.
  • By Ed Mullings

The presentation examines how the following data can be used to project risk across multiple T/A horizons allowing the turnaround planner to prioritize more effective inspections where needed:

  • Integrity Operating Windows and Safe Operating Limits
  • Key process variables affecting risk and remaining life i.e. crude slate changes
  • Risk transition times for:

    • Refinery
    • Process Unit
    • Asset type; i.e. relief device, fixed equipment, rotating, electrical, instrumentation
  • Implications of time-dependency on asset risk and remaining life
  • Increasing confidence in the data
  • The what-if analyses - analyzing risk across multiple turnaround horizons
  • - Lloyd's Register Conference, 2010

Risk Based Asset Management - Delivering and Sustaining Value Across a Mid-Sized Refining Enterprise (RMC-09-45)

Risk Based Asset Management - Delivering and Sustaining Value Across a Mid-Sized Refining Enterprise (RMC-09-45)

The business case developed for an RBI program - realized benefits and how the on-going value of the program is measured
  • By Jim McVay and Mike Hurley

The key to sustaining the value from a reliability-based mechanical integrity (RBMI) program begins with program ownership and continues with best practice management systems. We began our RBMI program with a pilot study in 2005 at one of our refineries. The pilot involved migrating our time-based fixed equipment inspection program to a RBMI program for eight process units. The study cost approximately $400,000 and was completed in less than four months. The return on that investment yielded a payback in less than twelve months and a value that exceeded $2.5 million in turnaround cost savings and quickly delivered almost seven million dollars in risk reduction.

  • - NPRA Reliability & Maintenance Conference & Exhibition, 5/19/2009

Integrity Operating Windows

Integrity Operating Windows

As with asset criticality ranking, defining integrity operating windows requires savvy facilitation of the subject matter experts that make up these cross functional teams (CFT). The presentation provides real world examples of what it takes (tasks) to deliver IOWs and the roles and responsibilities of the CFT.
  • By Ed Mullings
  • - LR Capstone Conference, 2009

Overview of Reliability Based Mechanical Integrity - Generating Value With RBI

Overview of Reliability Based Mechanical Integrity - Generating Value With RBI

This presentation examines several case studies to show actual measured value delivered from risk based inspection programs at DuPont and Tesoro Refining.
  • By Ed Mullings
  • - Capstone Conference, 2008

Leveraging the Corporate Asset Management Group/Business Partnership Leading to Improved Plant Productivity

Leveraging the Corporate Asset Management Group/Business Partnership Leading to Improved Plant Productivity

This presentation shows how the Rohm and Haas Asset Management Group (AMG) has provided value for over a decade to improve the company's overall plant productivity, reduce operating costs, and defer substantial capital investment.
  • By David Rosenthal, PE
  • - Benchmarking Best Practices in Maintenance and Reliability, Clemson University Conference, 11/30/2006

Overcoming Barriers to the Implementation of Risk-Based Inspection

Overcoming Barriers to the Implementation of Risk-Based Inspection

Address a variety of barriers that technical decision makers face when considering implementing risk based inspection programs.
  • By John Aller

The presentation addresses a variety of barriers that technical decision makers face when considering implementing risk based inspection programs including regulatory, insurers, organizational / cultural, resources, technology / software, data. In addition to his vast experience successfully delivering RBI programs and overcoming these barriers, John also introduces his recent book from the Materials Technology Institute, "Implementing and Evergreening RBI in Process Plants" which goes into even greater detail on these barriers and more importantly how to overcome them.

  • - California Boiler Inspectors Association Convention. Los Angeles, CA, May, 2005

Development of a Risk-Based Inspection Implementation Manual

Development of a Risk-Based Inspection Implementation Manual

The Materials Institute has developed a manual for implementing risk based inspection programs throughout the process industries.
  • By John Aller, Ricardo Valbuena, Michael Renner, and Emory Ford
  • - 20th Annual CCPS International Conference. Atlanta, GA, April, 2005

Implementing and Evergreening RBI in Process Plants

Implementing and Evergreening RBI in Process Plants

Common sense instructions on RBI value, implementation, design, and maintenance.
  • By Ricardo Valbuena, John Aller, Michael Renner, and Gene Feigel

This manual presents practical instructions on topics including:

  • How Do You Demonstrate the Value of RBI vs. Conventional Inspection Strategies to Your Company
  • How to Implement Risk-Based Inspection
  • RBI Considerations in Plant Design
  • RBI - An Insurer's Perspective
  • Maintaining or Evergreening RBI Programs After Implementation - an important topic since RBI should not be viewed as a one-time exercise but rather an on-going process that helps us manage inspection and mechanical integrity in our facilities

Input from both owner-users and vendors are included in this publication to ensure maximum objectivity.

  • - St. Louis, MO. Materials Technology Institute, 2005

Instrument Reliability Manual

Instrument Reliability Manual

This manual applies risk based inspection strategies for managing critical instruments in a chemical plant or refinery based on safety, business interruption and asset damage.
  • By Bernard Weber, Skip Callahan, Scott Jones, and John Aller

This manual applies risk based inspection strategies for managing critical instruments in a chemical plant or refinery based on safety, business interruption and asset damage. Normally identified in HAZOP and LOPA studies, the manual describes how this information can be captured and utilized as part of the RBI analysis. For example, instrumented functions (IF) (safety, control, layer of protection) are verified the same as a SIL Verification (sensor(s), logic solver /BPCS, final element(s)). The manual incorporates device reliability numbers from the OREDA handbook and describes how the database calculates an overall reliability calculation for a unit using the individual IF verification numbers.

  • - Materials Technology Institute, St. Louis, MO, 2005

The Integration of Risk-Based Inspection with Real Time Process Data

The Integration of Risk-Based Inspection with Real Time Process Data

Even before IOWs became a formal API RAGAGAP, thought leaders like John Aller were discussing the need for operational affects on fixed asset end of life.
  • By John Aller
  • - International Materials Technology Conference. Kuala Lumpur, Malaysia, March, 2004

Integrating RBMI With Your ERP

Integrating RBMI With Your ERP

Examine how consolidating the master equipment list into SAP, and integrating RBI eliminated $56k in annual costs but more importantly, mitigated human error in something as simple as data entry, that could potentially contribute to a catastrophic event.
  • By Michael Hurley

The Rohm and Haas' Deer Park site spent $56,352 each year for verifying and generating work orders/notifications for each of the 9,154 pieces of fixed equipment, pressure relief devices, flame arresters and piping circuits to be inspected annually. Prior to installing SAP, the plant had to manage six different databases including one for risk based inspection. The presentation examines how consolidating the master equipment list into SAP, and integrating RBI eliminated these costs but more importantly mitigated human error in something as simple as data entry, that could potentially contribute to a catastrophic event.

  • - Capstone Conference, 2004

Application of a Risk-Based Program to Optimize Relief Valve Maintenance

Application of a Risk-Based Program to Optimize Relief Valve Maintenance

The presentation describes the RBI model used to predict the deterioration in a pressure relief valve at a given point in time. The result? Ten million USD in savings over the next eight years for this ethylene manufacturer.
  • By John Aller, John Dugas, and Lee Allison
  • - AICHE 2003 Spring Meeting, March, 2003

A Comparison of Risk Based Inspection With a Conventional API-570 Inspection Program

A Comparison of Risk Based Inspection With a Conventional API-570 Inspection Program

This paper examines the financial benefits and more importantly, the risk reduction benefits of RBI compared to a conventional API-570 inspection program.
  • By Douglas Paneitz and John Aller
  • - ASNT Post Topical Seminar, June, 1999

Integrating Risk Based Inspection with Fitness for Purpose

Integrating Risk Based Inspection with Fitness for Purpose

Risk Based Inspection (RBI) was a relatively new technology in 1996. This paper provides some of the earliest benefit analyses for RBI following the completion of the base resource document that eventually became API 580 by one of the same authors of this paper.
  • By John Aller, Bill Zhu, and Doug Paneitz
  • - Pressure Industry Conference, Banff, AB, February, 1999

A Comparison of Risk-Based and Traditional Inspection Programs

A Comparison of Risk-Based and Traditional Inspection Programs

This paper compared the number of TMLs required for a traditional time based inspection program with risk based inspection and the resulting savings.
  • By John Aller, Douglas Paneitz, Jim Cleavinger and Larry Duke
  • - National Petroleum Refiners Association, Maintenance Conference, May, 1998

Using Risk Based Inspection to Focus on Corrosion Under Insulation

Using Risk Based Inspection to Focus on Corrosion Under Insulation

This paper discusses how inspecting for CUI could be better refined using a semi-quantitative RBI model.
  • By Doug Paneitz, John Aller and Bill Zhu
  • - Petro-Safe '98 Conference, January, 1998

Risk-Based Inspection, From New Technology to RAGAGEP

Risk-Based Inspection, From New Technology to RAGAGEP

This presentation discusses the the transformation of RBI as a base resource document to a Recognized and Generally Accepted Good Engineering Practice.
  • By John Aller, John Reynolds, and Tim Munsterman
  • - AICHE 1997 Spring Meeting, March, 1997

Integrating Risk Based-Inspection with Fitness for Purpose

Integrating Risk Based-Inspection with Fitness for Purpose

Risk Based Inspection (RBI) was a relatively new technology in 1996. This paper provides some of the earliest benefit analyses for RBI following the completion of the base resource document that eventually became API 580 by one of the same authors of this paper.
  • By John Aller, Bill Zhu, and Doug Paneitz
  • - Pressure Industry Conference. Banff, AB, February, 1997

Base Resource Document on Risk-Based Inspection: API Publication 581

Base Resource Document on Risk-Based Inspection: API Publication 581

The first edition of API PUBLICATION 581 was released in May 2000. This is the This document provides the ground breaking efforts of John Aller's vision as presented to API in May 1996.
  • By John Aller
  • - American Petroleum Institute, May, 1996

Risk-Based Inspection Methodology for the Petroleum and Petrochemical Industry

Risk-Based Inspection Methodology for the Petroleum and Petrochemical Industry

This paper represents some of the earlier collaborative efforts of two thought leaders in risk based inspection.
  • By J.T. Reynolds and John E. Aller
  • - Energy Week. ASME., 1996

Materials Engineering and Risk Management in Chemical Plant Operations

Materials Engineering and Risk Management in Chemical Plant Operations

The Publication discusses a study conducted at a 30 year old ethylene plant to optimize fixed equipment inspection and maintenance strategies prior to and during an upcoming planned shutdown.
  • By J.E. Aller and Marda N. Tayloe
  • - Materials Technology Institute of the Chemical Process Industry, 1995