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

Whether you have a mature time or condition based Mechanical Integrity (MI) program or no formal program at all, moving to a Risk-Based Inspection (RBI) approach can deliver real value.

These two scenarios represent opposite ends of the MI spectrum, and most facilities find themselves somewhere in between. No matter where you are on that journey, efficiency and cost savings is waiting on the other side of an RBI transition.

A Common Work Process

Before comparing the two approaches, it helps to start with a common MI workflow, one that applies to both time/condition-based and risk-based programs.

(Imagine your standard mechanical integrity process diagram here)

While the process might look like RBI-specific work, it's nearly identical for time-based MI. The only difference? In time-based MI, the "Risk Analysis" step is skipped.

Both approaches must address all anticipated damage mechanisms - as required by current API and other global inspection codes. What changes with RBI is how you prioritize those inspection tasks.

The Thought Experiment

Let's look at a simple example.

You manage 100 uninsulated carbon steel pressure vessels, operating below 350°F, under OSHA's PSM regulations.

Each inspection (of any type) costs $5,000, including production and maintenance support.

The vessels have only two damage mechanisms:

• Internal Corrosion
• External Corrosion

In a time-based MI program, each vessel gets three inspection tasks:

What Happens Under RBI

After more than 20 years implementing RBI across downstream assets, AOC's leadership team has developed reliable inspection reduction factors - based on actual project data.

Here's the short version:

• Piping and relief devices see the biggest reductions.
• Fixed equipment still sees strong efficiency gains.

Applying these factors to our 100-vessel example gives us:

Total savings per inspection cycle: $645,000.

What That Means

If you're transitioning from a mature time-based program, those savings represent real, measurable efficiency in your inspection planning and execution.

If you're starting from no MI program at all, RBI helps even more. Instead of rushing to inspect all 100 vessels, you only need to inspect the highest-risk ones first - maybe just 40–60% of the total population.

That means:

• Lower upfront inspection costs
• Faster compliance with PSM requirements
• A clear roadmap for future inspection cycles

And if inspections are prioritized by risk level each year, the long-term efficiency compounds even further.

The Takeaway

The old saying "walk before you can run" doesn't apply to MI programs.

Whether you're starting from scratch or optimizing a mature program, Risk-Based Inspection is the smarter, faster way to allocate your inspection resources and manage risk effectively.

Because in today's operating environment, efficiency and safety aren't competing goals - they're connected.

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