Asset Optimization Consultants

Achieving Unified Risk Management Through A Formal Acceptable Risk Policy

2026-03-27T15:07:00Z

This document outlines a unified approach to risk management through a formal acceptable risk policy. It defines risk tolerance, assigns decision authority by risk level, and requires escalating approvals for higher-risk decisions. The framework improves consistency, transparency, auditability, and resource prioritization across operations, engineering, and safety functions.

Unified Risk Framework Across MI, RCM, PHA, and SILSIS

2026-03-24T14:10:00Z

This document presents a unified risk framework integrating MI, RCM, PHA, and SIL/SIS into a single, risk-based system. It emphasizes a common risk matrix, shared failure modes, and centralized action management to eliminate fragmented governance. By linking equipment strategies, SIL validation, and MI data with closed-loop feedback and MOC, it enables consistent prioritization, aligned decision-making, and effective, real-world risk reduction.

Why is Management Of Change (MOC) so poorly executed

2026-03-17T15:56:00Z

Management of Change (MOC) under OSHA PSM is often poorly executed not due to lack of knowledge, but because it conflicts with operational realities. Production pressure, unclear definitions of change, weak field ownership, and procedural focus reduce effectiveness. Temporary and digital changes bypass controls, cumulative risk goes untracked, and approvals lack rigor. Without aligned incentives, clear boundaries, and post-implementation verification, MOC becomes a formality rather than a true risk control.

How to practically implement RBI for oil and gas production, gathering, and midstream facilities in the United States.

2026-03-11T15:29:00Z

This document presents a practical framework for implementing Risk-Based Inspection (RBI) and Mechanical Integrity (MI) programs for U.S. oil and gas production, gathering, and midstream facilities. It outlines lifecycle asset management practices aligned with API 510/570/653, API 580/581, PHMSA pipeline safety rules, and OSHA PSM to prevent loss of containment, detect degradation early, and maintain safe, reliable operations.

What process do I need to follow to confirm an equivalent inspection technique?

2026-03-03T20:34:00Z

This document provides a structured 10-step process to confirm, in a defensible manner, that an alternative inspection technique is equivalent to a baseline method. Aligned with API 580 and 581, it shifts the focus from technical opinions to a risk validation exercise.

Can you improve reliability focusing on safety 1st, environmental preservation 2nd, and production 3rd

2026-02-25T16:16:00Z

This paper examines whether prioritizing safety first, environmental protection second, and production third improves reliability in high-hazard industries. Drawing on field experience and industry practices, it shows that when risk truly drives work selection, organizations fix degradation earlier, reduce emergency work, and avoid forced outages—making reliability a byproduct of disciplined asset management.

Is your risk-based inspection (RBI) implementation 3rd party really qualified to do the job?

2026-02-17T21:52:00Z

Many Risk-Based Inspection (RBI) programs fail quietly when implementers prioritize software outputs over engineering judgment. This guide explores the critical markers of a qualified 3rd-party partner, from their ability to defend technical assumptions to their independence in making unpopular, risk-driven recommendations. Learn the essential questions to ask to ensure your program improves reliability rather than simply hiding risk behind calculations.

What Do Good Refining Corporate Cultures Look Like?

2026-02-08T22:04:00Z

In the refining industry, "culture" is often only analyzed after a failure occurs. However, a robust culture is defined by observable, repeatable behaviors and daily decisions made under pressure. This article outlines the seven practical attributes of high-performing refining organizations and demonstrates how alignment between leadership values and technical integrity creates a safer, more profitable operation.

Owner Management Support is Fundamental to Achieving What "Good Inspection" Looks Like

2026-01-28T00:00:00Z

A "good inspection" is determined by whether an organization allows the truth about equipment condition to surface and then acts on it. While NDE methods and codes are important, they cannot compensate for weak ownership. This post explores how management defines the purpose of inspection, controls quality variables like scope and follow-up, and establishes the psychological safety necessary for true risk identification.

Execution Failures: The Main Cause of PSM Loss-of-Containment

2026-01-21T00:00:00Z

Investigations by the CSB and industry standards like API RP 754 reveal that the majority of loss-of-containment events are preventable through disciplined execution. While degradation mechanisms are often well understood and corrective actions identified, disasters frequently occur because repairs are delayed or inspections are deferred. This post explores how organizational accountability and robust governance can prevent these systemic breakdowns in PSM execution.

What Does "Good" Actually Look Like in Inspection?

2026-01-14T00:00:00Z

In mechanical integrity, we often confuse activity with assurance. A thick report or "100% coverage" means nothing if the inspection tool cannot "see" the damage morphology. This post explores what "good" inspection actually looks like by shifting the focus toward meaningfully reducing uncertainty. Learn the critical questions every program must answer and how to align NDE physics with specific damage mechanisms to prevent loss-of-containment events.

Got Out of 2025 with Only 9 U.S. Refinery Fires and Explosions - A Safety Checkpoint Worth Noting

2026-01-07T00:00:00Z

In 2025, the U.S. refining industry recorded approximately nine publicly reported fires and explosions. Notable events at Chevron’s El Segundo facility and HF Sinclair’s Navajo refinery underscore the persistent risks associated with mechanical failure and process safety gaps. This report analyzes why these statistics, though seemingly modest, demand a continued focus on maintenance and hazard identification to prevent future high-consequence events.

Replacing Internal Visual Inspection with Non-Intrusive Techniques in Refineries: Practical Recommendations

2025-12-17T00:00:00Z

While Risk-Based Inspection (RBI) promised to reduce intrusive vessel entries, corporate risk aversion and rigid API standards have hindered progress. This post examines why internal visual inspection (IVI) remains the standard despite its human-factor limitations. We analyze the Probability of Detection (POD) for advanced NII technologies - including PAUT, PEC, and Corrosion Mapping - to propose a roadmap for achieving technical and regulatory equivalency in refinery asset integrity.

Why Companies Prioritize Other PSM Elements Over Mechanical Integrity

2025-12-10T00:00:00Z

Mechanical Integrity (MI) is one of the most critical elements for preventing catastrophic events, yet it is routinely identified as one of the weakest in Process Safety Management (PSM). This article details 10 realistic reasons - from economic pressure and production bias to leadership knowledge gaps and the invisibility of degradation - why organizations chronically deprioritize MI work over other, more administrative PSM elements. Discover why companies focus on paper compliance instead of asset integrity.

Why is Mechanical Integrity So Important to Process Safety Management?

2025-12-03T00:00:00Z

Mechanical Integrity (MI) is the crucial foundation of Process Safety Management (PSM). Major accidents overwhelmingly result from equipment failures like ruptured vessels or corroded piping. This post details eight essential reasons why a robust MI program is vital, including preventing loss of containment , ensuring safeguards function as designed , and meeting mandatory OSHA and EPA compliance.

Are U.S. Refinery Incidents Increasing? A Clearer Look at the Data, the Debate, and When the Trend Began

2025-11-26T00:00:00Z

Public data suggests U.S. refinery fires and explosions have increased significantly since 2018, with some analyses showing a tripling of incidents. However, industry process safety metrics indicate improvement. This article explores the evidence, why the datasets conflict, and the start of the upward trend.

Why We Still See Refinery Fires - More Than 30 Years After OSHA 1910.119

2025-11-20T00:00:00Z

Despite OSHA's 1992 Process Safety Management (PSM) standard, refinery and chemical plant fires continue to make headlines. This post breaks down the seven systemic reasons why these incidents persist. We explore how mere compliance, aging infrastructure, weak safety culture, and reactive risk management prevent the elimination of catastrophic risks.

PHMSA vs OSHA for Hydrocarbon Facilities

2025-11-12T00:00:00Z

Hydrocarbon facilities in the U.S. frequently face overlapping regulation from the Pipeline and Hazardous Materials Safety Administration (PHMSA) and the Occupational Safety and Health Administration (OSHA). While PHMSA primarily governs transportation safety via pipelines (49 CFR 190-199), OSHA focuses on worker safety and health within facilities, including Process Safety Management (PSM). This post clarifies their distinct scopes, common jurisdictional boundaries (e.g., at the first valve inside a facility), and provides tips for operators to integrate their compliance programs.

Why Moving to RBI Makes Sense - No Matter Where You Start

2025-11-05T00:00:00Z

Discover how transitioning to a Risk-Based Inspection (RBI) approach can deliver real value and significant cost savings over traditional time/condition-based Mechanical Integrity (MI) programs. We use a simple 100-vessel example to show a potential $645,000 savings per inspection cycle and discuss how RBI accelerates compliance and prioritizes safety-critical tasks.

Leveraging AI to Accelerate Data Collection in Risk-Based Inspection Projects

2025-10-27T00:00:00Z

Data collection is an RBI project bottleneck, often taking a very significant percentage of total effort due to manual interpretation of old, varied engineering documents. AOC developed AI-driven tooling to automatically extract, classify, and normalize this data, achieving a very high accuracy and significantly streamlining the process for faster, more reliable RBI implementation.

Proposal for Individual Damage Mechanism Risk Calculation in API 581

2025-10-22T00:00:00Z

In 2021, I published a proposed change to the API 581 PoF calculation. While I believe API 581 is solid as a recommended practice, I believe that inspection planning can be further optimized and fine-tuned to adapt to organizational needs. Since then, the original article has prompted a variety of comments and questions and so I have rewritten the original article for, hopefully, a little more clarity, and I have consolidated the top questions along with my comments.

API 580 vs API 581: Which RBI Approach Is Right For You?

2025-10-15T00:00:00Z

Deciding between API 580 and API 581 for Risk-Based Inspection? This guide helps you choose the right approach for your site's unique needs. Learn whether the qualitative, experience-based framework of API 580 or the data-driven, semi-quantitative methodology of API 581 is the best fit for your facility.

The Top Three RBI Risks That Cannot Wait for a Budget Rebound

2025-10-01T00:00:00Z

When organizations face budget cuts, they may postpone projects, but certain risks are too critical to delay. This post highlights three such Risk-Based Inspection (RBI) risks that demand immediate attention: high-risk equipment, Corrosion Under Insulation (CUI), and overdue critical inspections. Acting now can safeguard people, assets, and the bottom line from costly failures.

Why We're Lowering Our Rates - and Why Now?

2025-09-24T00:00:00Z

As the post-COVID downturn has continued, we have seen former, current, and future clients struggle. Recognizing this, and taking advantage of new efficiency gains, we are reducing our rates on new projects so that we can further support our friends in the industry.

Risk Strategies for Pressure Retaining Equipment

2024-07-11T00:00:00Z

What are equipment/inspection strategies in relation to mechanical integrity (MI) and risk based inspection (RBI)? It is a simple answer, but can be complicated to produce a documented set. API RP 581 has gone as far as the RAGAGEP can go since it is up to the Owner/User to define them as they are responsible for their risk. Knowing strategy/effectiveness tables are likely to be used without modification therefore AOC created a set that can be used as inspection recommendations out of the box.

API 580 (4th edition) Required Elements

2024-06-17T00:00:00Z

What are the requirements of API 580, 4th edition? It can be tedious sorting out the "shalls" from the "shoulds". Fortunately, our training team has been kind enough to do this for us. But don't tell them I told you.

Hidden Benefits of Risk Based Inspection (RBI)

2021-05-26T00:00:00Z

The prime objective of a Site's Mechanical Integrity programme should be to eliminate any unintentional releases of stored energy. Most Sites implement Risk Based Inspection for three obvious reasons. However, as well as these reasons other less obvious but still positive benefits can be achieved through the implementation. These less obvious reasons could be equally valuable to the efficient operation of the Site.

National Regulation 13 in Brazil

2021-03-31T00:00:00Z

Although Risk Based Inspection is well recognised as a good practice it has not been adopted by every country in the world. Brazil in particular has its own Regulatory Standard known as NR13 which it uses to set out some minimum time-based safety standards for the management and inspection of steam boilers, pressure vessels, some metal storage tanks and their interconnecting pipes. Hopefully the adoption of Risk Based Inspection is not far away.

A Practical Way to Incorporate the New PHMSA Underground Gas Storage Requirements Into your MI Program

2021-03-11T00:00:00Z

PHMSA has out a new rule for underground natural gas storage facilities (UNGSFs). This is practical approach to incorporating gas wells into your mechanical integrity program with the rest of your surface and subsurface assets.

Plant Management 101: Common Work Processes

2021-03-03T00:00:00Z

This article deals with the dysfunctionality found in many refineries, chemical plants, and other production facilities. This can lead a facility to not reaching its value and reliability goals. One of the main reasons for this dysfunctionality is facility departments not using a common asset management work process.

Asset Value Management vs Asset Performance Management

2021-02-16T00:00:00Z

VP of Technology, Mike Hurley, looks at the concept of Asset Value Management in the financial sector and compares it with Asset Performance Management (APM) with respect to our industry. He goes further to propose a new definition of AVM as applicable to the petrochemical industry and begins the conversation of AVM vs APM.

Proposed API 581 Inspection Plan Optimization Example

2021-02-04T00:00:00Z

This article deals with a proposal for a risk analysis option that allows for individual damage mechanism risk calculation. This is an example of how it can be applied and how it domonstrates value.

Proposed API 581 Inspection Plan Optimization

2021-01-27T00:00:00Z

This article deals with a proposal for a risk analysis option that allows for individual damage mechanism risk calculation. This allows for these individual damage mechanism risks to be compared to a risk target that when reached generates an inspection task with its own due date.

RBI Value: Both Transitioning And From The Start

2021-01-21T00:00:00Z

This article deals with the value of going directly to an Risk Based Inspection (RBI) program from nothing or transitioning from a time/condition based program and demonstrates that an RBI program is the efficient use of resources.

Possible PHMSA and OSHA Jurisdictional Clarity

2021-01-14T00:00:00Z

PHMSA has out for comment, draft document information, that clarifies its jurisdiction in relation to OSHA for Midstream Processing Facilities.

Other Benefits of Risk Based Inspection Implementation

2020-06-09T00:00:00Z

Aside from the direct benefits of implementing a Risk Based Inspection (RBI) program such as cost savings, optimized inspection planning, and reduced risk, RBI programs have a number of other benefits. This article looks at some of these secondary benefits including equipment verification, better organization of data, deeper understanding of facility status, and improved inter-team collaboration.

Guidelines for Providing Process Conditions for RBI - Part 7: Environmentally Assisted Cracking and RBI

2019-09-01T00:00:00Z

The 7th installment in our series covers environmental cracking. James Leonard, RBI Team Leader, discusses the additional process data that may be needed to determine environmental cracking damage potential when environment, stress, and metallurgy are so alligned so as to indicate susceptibility to this damage mechanism.

Guidelines for Providing Process Conditions for RBI - Part 6: High Temperature Hydrogen Attack (HTHA)

2019-08-26T00:00:00Z

Gathering adequate process data to determine HTHA susceptibility is sometimes a difficult and time consuming task. Therefore a simple screening can be performed to determine if more detailed process data is required. Senior Corrosion Specialist, Vibha Zaman, discusses the screening process and what factors to consider when more data is required.

Insights on Improving Inspection Effectiveness

2019-07-30T00:00:00Z

Don Conger, Senior Consultant at AOC, discusses the inherent subjectivity of evaluating inspection effectiveness. Too much subjectivity can lead to inconsistent results in your inspection effectiveness evaluation. This subjectivity can be mitigated through up-front activities including training, documentation, quality control, and planning.

Guidelines for Providing Process Conditions for RBI - Part 5: Low Temperature Damage Mechanisms

2019-06-17T00:00:00Z

In our fifth article in our series on providing process conditions for Risk Based Inspection, one of our senior corrosion specialists discusses several damage mechanisms that are often associated with equipment operating at low temperatures. As with the other topics of this series, we point out additional factors, beyond the standard inputs, that need to be considered when dealing with equipment in this class.

Guidelines for Providing Process Conditions for RBI - Part 4: High Temperature Damage Mechanisms

2019-05-07T00:00:00Z

In this fourth, of our eight-part series covering various guidelines for providing process conditions for Risk Based Inspection (RBI), a senior corrosion specialist discusses two groups of damage mechanisms that can result from high temperatures. We note that the standard inputs to your RBI software are not always sufficient to capture these damage mechanisms and provide some additional guidelines to take into consideration.

Announcing Our New Inspection Services Group

2019-03-26T00:00:00Z

Scott Jones, President of AOC, talks about our decision to add an Inspection Service Group to our team. This addition to AOC is indicative of our continued commitment to providing high quality services to our clients and partners.

Guidelines for Providing Process Conditions for RBI - Part 3: Process Fluids and Consequence Models

2019-02-28T00:00:00Z

In this third of our eight part series covering various guidelines for providing process conditions for RBI, one of our senior consultants discusses process fluids and consequence models with respect to Risk Based Inspection. This article identifies several factors to consider when selecting a representative fluid for the determination of consequence.

5 Things to Consider When Choosing Your API Training Provider

2019-01-22T00:00:00Z

Our VP of Performance and Learning discusses some things to investigate when evaluating training providers for your API learning needs. While there are many vendors out there that bill their ability to provide training for American Petroleum Institute (API) certification and education, not all vendors are created equal. Some up-front research can go a long way toward a high-quality learning experience.

Goal: 100% API 580 Certified

2019-01-15T00:00:00Z

Scott Jones, President of AOC, talks about our goal of having 100% of our RBI staff certified to API 580. A long-standing vision of AOC, we are well on our way to meeting this goal. This certification demonstrates industry recognition of our consultants and is indicative of our commitment to providing high quality services to our clients.

Guidelines for Providing Process Conditions for RBI - Part 2: CUI and How it Relates to Risk Based Inspection

2019-01-08T00:00:00Z

In this second of our eight part series covering various guidelines for providing process conditions for RBI, one of our senior consultants discusses Corrosion Under Insulation (CUI) and how it relates to Risk Based Inspection. This article identifies several factors to consider during data collection as well as points out some guidelines for selecting potential inspection locations.

Risk Analysis: Good In, Good Out - A Risk Analyst's View

2018-11-16T00:00:00Z

An AOC Team Lead reflects on the importance of ensuring your data is accurate and on the impact that having poor data can have on your risk analysis. Having even just one or two erroneous data points can make all the difference in the risk assigned to an asset and the subsequent inappropriate assignment of maintenance and inspection resources. Assigning low risk to a high risk asset because of bad data can result in unexpected and painful consequences.

Guidelines for Providing Process Conditions for Risk Based Inspection (RBI) Implementation and Revalidation

2018-10-24T00:00:00Z

Our Senior Corrosion and Mechanical Integrity specialists provide useful insights into the determination of the process information to be used for Risk Based Inspection (RBI) projects. Incorrectly assigning process conditions for a particular piece of equipment can result in overlooking a variety of applicable damage mechanisms and a skewed calculation of risk. Guidance derived from experience is provided to ensure the process conditions are appropriately identified for a number scenarios that have an impact on damage mechanisms and consequence calculations. This is the first in this eight-part series.

Risk Based Inspection Seen Through the Eyes of the Experts

2018-08-27T00:00:00Z

An AOC Consultant facilitates a virtual panel of Risk Based Inspection (RBI) experts to gain insight into the challenges and value of RBI implementation. Our experts consider why organizations implement RBI, common challenges, and strengths of an RBI champion.

Qualitative RBI of a Commercial Refrigeration System

2018-08-07T00:00:00Z

How the application of qualitative RBI helped a client prioritize equipment damage mitigation in order to effectively scope a refurbishment project and achieve their system reliability goals. This scenario highlights a significant problem for some refrigeration system owner/users who may be maintaining their assets as prescribed but are unaware of the damage mechanisms that could affect the reliability of their assets and safety of their personnel.

Process Safety Management (PSM) and Commercial Refrigeration

2018-07-18T00:00:00Z

Organizations that have commercial refrigeration facilities need to be aware of new OSHA Process Safety Management (PSM) regulations. Since these facilities are something of an outlier, when compared with chemical processing and refineries, it may not be readily apparent. However, anyone with large quantities of anhydrous ammonia at their facilities needs to prepare for potential NEP audits.

Skills Validation - Moving from Learning to Performance

2018-07-12T00:00:00Z

Training alone may not necessarily improve team performance. Skills Validation is an effective tool for realizing the benefits of training. What are the benefits of Skills Validation and how do you implement it?

Dynamic Risk - Mechanical Integrity

2018-06-26T00:00:00Z

Things are always changing. Including your risk profile. AOC helps companies manage their dynamic Mechanical Integrity (MI) risk. AOC can help you implement and sustain an effective Risk Based Inspection (RBI) program.

The Difference Between Safe Operating Limits (SOL) and Integrity Operating Windows (IOW)

2018-06-18T00:00:00Z

An AOC consultant, a process engineer, and a reliability engineer discuss the differences between Safe Operating Limits, Standard Limits, and Integrity Operating Windows.

Risk Management for Kids

2018-06-12T00:00:00Z

One of our consultants brings Risk Based Inspection into the grade school classroom for Career Day.

"What you do is important" - A young NDE tech's journey

2019-03-27T00:00:00Z

Wayne Elliott, leader of our Inspection Group, tells the story of how a young NDE technician's critical discovery caused a large shell and tube exchanger to be pulled and returned to the fabricator. Even the most routine, run-of-the mill job can have a significant impact. No matter where one falls in the hierarchy, each team member's role is important. Avoiding complacency and staying diligent and attentive to detail can make a big difference.

Steam System Risk Mitigation Using Risk Based Inspection

2019-01-30T00:00:00Z

A review of AOC's partnership with the Dow/DuPont Sabine River Facility, Rob Sladek and Gerald Skinner were part of the team tasked to perform an RBI implementation on the plant's steam system, the goal of which was to mitigate risk and reduce maintenance costs associated with the utilities service. Steam: a great success story for an often overlooked, but critical, operation within the plant. Presented on January 30, 2019 at the API 2019 Inspection and Mechanical Integrity Summit.

Risk Based Inspection Yields Big Savings for Gulf Coast Chemical Plant

2018-09-13T00:00:00Z

A Gulf Coast-based chemical plant recognized the need to have all their fixed equipment, piping, and pressure relief devices converted from a conventional API inspection program into a Risk-based approach. Through the RBI implementation, they realized a 65% reduction in inspection requirements while projecting an estimated $3.2M reduction in maintenance cost and a risk reduction savings estimated at $4.6M over the next 10 yrs. Additionally, the opportunity to increase turnaround intervals had a projected cost savings of $8M over 10 yrs.