Risk Based Inspection Yields Big Savings for Gulf Coast Chemical Plant

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.

Risk Based Inspection Yields Big Savings for Gulf Coast Chemical Plant

A strong ROI is the first step in building a case to introduce a new program into a facility. This client recognized the need to convert their existing conventional API program into a manageable Risk Based Inspection (RBI) program for all their fixed equipment, piping and pressure relief devices. This project included a review of all piping circuits, collecting all vessel, piping and PSV data and review inspection histories. This data was evaluated during the corrosion study and used to perform a risk assessment and 15 year inspection plans for these assets. By implementing an RBI program using a software program for management, this chemical plant will save approximately $15,000,000 over ten years. The cost benefit is realized by reducing the amount of fixed equipment inspections, relief device maintenance being performed each year, and reducing the risk associated with these assets. Through the implementation of a program based on anticipated damage mechanisms, the facility was also able to extend turnaround intervals and realize a 35% reduction in fixed equipment that required internal inspections.

The value proposition below is based on a 10-year plan with the anticipated cumulative risk reduction per asset count:

Risk Based Inspection (RBI) Yields Big Savings

The RBI implementation has enabled this chemical plant to improve the reliability, safety and integrity of its process equipment while saving the company millions of dollars.

Case Study Inquiry

Related Services

Risk Based Inspection (RBI) Implementation and Planning

AOC has delivered thousands of sustainable Risk Based Inspection (RBI) programs earning the trust of owner operators.

Reliability Based Asset Management - AIM for all asset families

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

Master Data Management and Data Conversion

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

Related Tools

API 580 Work Process Quiz

How well do you know RBI? Take this short quiz to test your knowledge of the API 580 risk-based inspection (RBI) work process.

RBI Potential Savings Calculator

Create mechanical integrity (MI) program value rather than it being seen as a necessary cost to minimize.

Related Training

RBI Concepts - Return on Net Assets (RONA)

Asset Integrity Management - how you perform at the plant level affects those goals set at the board room

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

RBI/MI Overview

A high level overview intrucing Mechanical Integrity and Risk Based Inspection

API 580 RBI Overview

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

Related Knowledge

Hidden Benefits of Risk Based Inspection (RBI)

What are the hidden benefits of implementing Risk Based Inspection?

Asset Value Management vs Asset Performance Management

A look at how the financial sector's concept of Asset Value Management can be applied to the petrochemical industry.

RBI Value: Both Transitioning And From The Start

A look at how RBI adds value whether you are just starting out or transitioning from a traditional methodology.

How to Incorporate the New PHMSA Underground Gas Storage Requirements

This is a practical approach to incorporating the new PHMSA gas well rules into your integrity program with the rest of your surface and subsurface assets.

Plant Management 101: Common Work Processes

A dysfunctionality found in many refineries, chemical plants, and other production facilities, is a lack of common asset management work processes.

Proposed API 581 Inspection Plan Optimization Example

An example to compliment our earlier proposal for a risk analysis option that allows for individual damage mechanism risk calculation in API 581

Proposed API 581 Inspection Plan Optimization

A proposal for a risk analysis option that allows for individual damage mechanism risk calculation in API 581

Other Benefits of Risk Based Inspection Implementation

A look at several of the secondary benefits of Risk Based Inspection

Guidelines for Providing Process Conditions for RBI - Part 7: Env Cracking

Additional process data may be needed when environment, stress, and metallurgy are so alligned so as to indicate susceptibility to environmental cracking.

Guidelines for Providing Process Conditions for RBI - Part 6: HTHA

A simple screening to determine HTHA susceptibility and factors to consider when more data is required.