Risk-based inspection (RBI) is the process of developing an inspection plan based on knowledge of the probability of equipment failure and its consequences. Risk Based Inspection involves the ranking of site-acceptable risk levels and operating limits. Assessed risk levels are used to develop a prioritized inspection plan. Inspections of this nature can be qualitative (items are reported in descriptive values and are discrete in nature, such as smoothness, color, “ok”, or “not ok”), quantitative (when data is measured and reported in numerical values and are continuous in nature, such as temperature, diameter, or length) or semi-quantitative (has some qualitative measurements).
Risk Based Inspections are common in engineering, particularly in the Oil and Gas industries. Assets for which RBIs are valuable include storage tanks, onshore pipelines and structures, and power generation components such as steam turbines, gas turbines, and heat recovery steam generators.
With RBI software, a Punch List (a Punch List is a compendium of all inspection items that failed an inspection) is generated during or after an inspection which lists the criticality levels of the items inspected so that management can make informed decisions for actions.
A Punch List report identifies criticality levels during a Risk Based Inspection
Risk Based Inspection Benefits
- Use inspection resources more cost-effectively
- Better visibility into the health of your critical assets
- Reduce risk of failures
- Improve the reliability of the equipment
- Identification of operational risks associated with equipment degradation
- Ensure compliance with environment and safety regulations
- Ability to plan maintenance activities and avoid unplanned shutdowns
FAQs
Risk-based inspection is an inspection-planning method that prioritizes equipment according to risk. It considers both the probability of an equipment failure and the potential consequences to determine which assets require the greatest inspection attention.
A risk-based inspection program is a documented process for evaluating equipment risk and converting the results into inspection priorities and plans. It defines which assets are included, identifies credible damage mechanisms, assesses failure probability and consequences, and establishes inspection or risk-mitigation actions.
The RBI methodology combines probability of failure with consequence of failure to determine an asset’s relative risk. Teams collect equipment and operating data, identify damage mechanisms, evaluate possible failure scenarios, rank assets, and create inspection plans that concentrate resources on the highest-risk equipment. API RP 580 describes the elements used to develop and maintain an RBI program, while API RP 581 documents a quantitative RBI methodology.
A defensible RBI program should maintain its scope, asset data, damage-mechanism assessments, probability and consequence calculations, assumptions, risk rankings, inspection plans, completed findings, mitigation actions, and reassessment history. It should also identify the people responsible for the assessment and document their qualifications.
Refineries and oil and gas operators use RBI to prioritize inspections of pressure vessels, piping, storage tanks, pressure-relief devices, and other safety-critical equipment. Assets presenting higher risk receive greater inspection attention, while lower-risk equipment can be managed according to documented risk and condition.
RBI determines inspection timing from the asset’s risk, active damage mechanisms, operating conditions, previous findings, and expected deterioration. Critical assets may require shorter inspection intervals, while stable, lower-risk assets may justify longer intervals when permitted by applicable requirements. Teams can use an inspection interval calculator as a planning aid, but the final interval must follow the applicable engineering and regulatory requirements.
Risk-based inspection software organizes asset information, risk assessments, inspection plans, findings, and reassessment records in one system. Field Eagle’s risk-based inspection software connects inspection evidence and condition history to individual assets so teams can prioritize work using documented risk.
The American Petroleum Institute offers the API 580 Risk-Based Inspection certification for qualified inspectors, engineers, and other petrochemical professionals. The certification validates an individual’s RBI knowledge, but the personnel qualifications required for a particular program still depend on the employer, asset, jurisdiction, and applicable standards.
