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? We will answer these questions and examine all the components that make up delivering and being able to sustain an RBI asset integrity management program as a best practice.
Risk Based Inspection (RBI) - A Mechanical Integrity Best Practice

As a mechanical integrity best practice, the following aspects of RBI will be explored:

Current asset integrity practices, roles, responsibilities and examples of gaps that may exist, as well as the importance of developing a rapport with those earmarked to manage the new program.

Develop procedures and work processes should include as a minimum the following parts:

  • MI Policy and Strategy
  • Training Personnel
  • Managing Information
  • Controlling Documents
  • MI System Description

Work Flow should include as a minimum the following parts:

  • Identify Asset Integrity (AI) processes and equipment
  • Collecting Data and Information
  • Determining Potential Degradation Mechanisms/Failure Mechanisms
  • Assessing Risk -if required
  • Developing Inspection and Maintenance Plans
  • Executing Inspection and Maintenance Plans
  • Evaluating Activity Results
  • Communicating Results
  • Measuring Performance

Quality Procedures

Equipment Strategies and installation procedures

Task Procedures

Training

Lunch and Learn Inquiry

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?

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.

OSHA Compliance

What do you do when you are on the job for six weeks and you have a toxic leak twice the release of the recent DuPont event? Not to mention the fact that it is only 1992 and OSHA 1910.119 is just getting started...

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.

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.

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

Mechanical Integrity Assessments

An interdependent assessment of your people, process, and technologies for a confident path forward

Integrity Operating Window Development

Key parameters and mitigating actions for variables that may dramatically affect the intended design life of your asset

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

RAM, RCM, FMEA, FMECA and Bad Actor Analysis

AOC delivers the policies, procedures, work processes, knowledge and actions such as preventive maintenance, predictive maintenance, and condition monitoring tasks.

RBI Implementation and Inspection Planning

AOC has delivered thousands of sustainable RBI programs earning the trust of owner operators.

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

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?

RBI/MI Overview

What is Risk Based Inspection?

Equipment Data Collection

What information do we need to collect to support a Mechanical Integrity and/or RBI program?

Damage Mechanism Identification and Review

How do we identify and quantify the damage mechanisms that affect our equipment?

Estimate Risk

How do I estimate risk using the information that I have?

Activity Planning, Execution, and Evaluation

How do I plan and perform inspections and tests?

Manage Changes and Communicate Results

How do I ensure that my MI/RBI program is up to date and communicate to stakeholders?

Reliability Revolution - Measuring the Value of an RBI Program

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

Value Proposition

Developing the value proposition and business case for an RBI program

Asset Integrity Management Assessments

How important are they?