RBI Implementation and Inspection Planning

As Meridium Certified Service providers and technical experts of API 580, 581, 584 and other RBI technologies, AOC has earned the trust of owner operators by delivering sustainable value through learning management. Our clients' direct personnel and contractors undergo just-in-time training modules and performance measurement to master each step of best-practice RBI technologies. Their success is evident in PSM compliance, incident reductions, and asset reliability and productivity improvement.
RBI Implementation and Inspection Planning

The consultants at AOC have implemented hundreds of risk-based projects to maintain fixed equipment assets. The major benefits that are evident to our clients include:

  • PSM compliance
  • Reduction of safety, health, and environmental incidents
  • Improvement of asset reliability and productivity

Our method for success is our Learning Management approach. We share our experience as Meridium Certified Service providers and our technical knowledge of API 580, 581, 584 and other RBI technologies with our clients' people. With the use of just-in-time training modules specific to these technologies, our clients' direct personnel and contractors master each part of best-practice RBI work processes:

  • Plan of inspection that is focused more on higher- that lower-risk assets
  • Documentation and management of inspections that are complete, consistent and integrated
  • Identification of risks of equipment failure and efforts for risk mitigation
  • Alignment of damage mechanisms driving the risk of loss of containment with the inspection strategies

Our approach to learning management is perfected with the measurement of performance. We utilize skills assessment tools to analyze and perfect the performance of the RBI program and the people that manage the program.

With a combination of experience and expertise, AOC has earned the trust of owner operators by delivering sustainable value through learning management.

Why RBI?

  • Equipment failures cost the U.S. refining industry over $4 billion per year
  • Two-thirds of those costs are associated with failures of fixed equipment
  • The average refinery has a risk of $25 million per year due to failures of fixed equipment
  • Two-thirds of those costs are associated with piping failures
  • RBI implementation results in a 77 percent measurable reduction of high potential incidents at major chemical sites over the following two years

As former Capstone founders and Meridium consultants, we have implemented hundreds of RBI programs, delivering measurable benefits to our clients that:

  • Focus risk mitigation of key assets
  • Improve maintenance costs/work selection
  • Align inspection strategies with identified/predicted damage mechanisms and industry standards
  • Provide an enterprise view of risk management eliminating limited capability database systems and inefficient inspection efforts
  • Focus on system corrosion monitoring rather than equipment monitoring
  • Optimize field inspections: reduced TMLs, extended inspection intervals, etc.

Whether utilizing all AOC personnel or some combination of our client's resources, our method for delivering early time to value and early ownership is Learning Management. Learning Management delivers just-in-time training modules specific to the client's choice of RBI technology, while our business process best practices, RBI work instructions, skills validation and mentoring align our clients' personnel and contractors each step of the way from project execution through sustainable program management.

With our extensive knowledge as plant engineers, we are able to deliver meaningful KPIs that we have documented through co-authored papers with our clients at reputable venues such NACE, AIChE, CCPS, NPRA and AFPM to mention a few. And finally, our consultants have and continue to earn the trust of our clients which is why many of our clients have been with us well over fifteen years.

Related Knowledge

The MI Assessment - Understanding Your Mechanical Integrity Goals

Compliance? | Best Practice? | Risk Reduction? | One Step at a Time? | Capture Personnel Knowledge? | All Of The Above?

Operational Readiness - Ensuring the Transition from Construction to Startup to Operations and Maintenance

Design basis RBI? Why not optimize all your asset families prior to RFSU?

Data Mining, Management, and Migration

Sometimes moving millions of data fields from ten different databases to another seems like trying to get a thousand birds to leave the branches of one tree and land on just the right branches of another.

Production Loss Accounting - Heat Exchanger Bad Actor Analysis

Heat exchanger failures contribute to over $146M in losses for a large refining enterprise.

Risk Based Inspection: What To Expect

Significant findings, even after ten years.

Meaningful KPIs

Anything worth doing is worth doing right.

Storage Tank RBI

How many RBI studies have been completed on above ground storage tanks (ASTs)? We have completed hundreds.

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.

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.

Implementing RBI in Remote Locations

The importance of understanding risk and the significant value attainable through the implementation of risk based inspection (RBI)

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

Implementing and Evergreening RBI in Process Plants

Common sense instructions on RBI value, implementation, design, and maintenance.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

Related Services

Operational Readiness and Maintenance Strategy Development

Development of maintenance strategies, recommendations, and plans to implement best practices and increase asset life

Master Data Management and Data Conversion

Innovative technology that allows quick, efficient extraction of data into a knowledge-centric world

Mechanical Integrity: Development of Procedures, Work Processes, and Human Performance Improvement

A maintenance system designed in which elements work together as a quality system for maximum returns

Damage Mechanism Review / Corrosion Study

One of the most important steps in an RBI project is the corrosion study or damage mechanism review.

End-of-Life, Remaining-Life, and Fitness-for-Service Assessments

When evaluation of inspection results suggest that an asset is near its end of useful life, Fitness for Service evaluations can determine if the asset us suitable for continued operation.

Corrosion Control Planning

Achieving zero corrosion-related loss of primary containment in the refining industry.

Reliability Based Asset Management - AIM for all asset families

Asset Integrity Management for all asset families - Rotating, Electrical, Instrumentation, and Fixed Assets

Related Training

RBI Work Process Using RBMI

How do I use RBMI to perform MI/RBI tasks?

Risk Analyst Training for RBMI

How does RBMI software estimate risk?

Managing and Sustaining an RBI program using RBMI

How do I manage and sustain my MI/RBI program using RBMI software?

Meridium Mechanical Integrity Work Process Training

How do I use Meridium to perform MI/RBI tasks?

Risk Analyst Training for Meridium RBI

How does Meridium RBI software estimate risk?

API 580 RBI Training

Is our Risk Based Inspection (RBI) program aligned with the API 580 Recommended Practice?

API 580 RBI Training (Online)

Need to study API Recommended Practice 580 on your own?

API 580 RBI Overview

What impact does Risk Based Inspection (RBI) have on my organization?

Ensuring People Performance

How do I transfer knowledge to my team and verify their skills?

So You Want To Be an RBI Risk Analyst

What does a Risk Analyst do and how do I become one?

Risk Based Inspection (RBI) - A Mechanical Integrity Best Practice

What are your goals for RBI? How will you measure your success? How will you sustain that success?

Learning Management

Are your inspectors empowered to sustain your RBI program after the service provider completes their fixed price contract?

Reliability Revolution - Measuring the Value of an RBI Program

How does one of the largest chemical manufacturers measure the value of their RBI program?

Requirements for Becoming a Risk Analyst

What do I need to do to be a Risk Analyst?

Value Proposition

Developing the value proposition and business case for an RBI program

The Meridium MI Suite

How to achieve an end to end RBI program in less than six months

Learning Management

Achieve an RBI program complete with KPIs, Best Practices, and Skills Validation