Risk-Based Inspection (RBI) is a process used to develop an inspection plan based on awareness of the risk of equipment failure in the maintenance of facilities and to support inspection decision-making. Risk-based inspection has its greatest impact on managing the timing of maintenance activities on mechanical systems and is one of the key tools for moving towards an effective physical asset management strategy. By applying this approach, it is possible not only to enhance safety, but also to significantly reduce inspection and maintenance costs and, by reducing incidents, to help protect the environment.

The art of RBI can be seen in defining the acceptable level of risk and determining the maximum on-stream time for an operating unit before this risk level is reached.

Key benefits of using RBI include:

• Increased safety

• Reduced technical inspection costs and reduced risk of equipment failure

• More accurate planning of inspections and maintenance

• Effective management of intervals between technical inspections and periodic maintenance

• Development of inspection programs that are optimized in terms of both time and cost

• Development of maintenance schedules based on an acceptable level of performance and risk

Many industrial complexes, especially oil, gas and petrochemical plants worldwide, have implemented RBI techniques. Reports indicate that the proper implementation of RBI has enabled these plants to better manage the intervals between major overhauls and has resulted in substantial financial savings.

Furthermore, in each operating unit, RBI makes it possible for approximately 10% to 40% of equipment to be inspected and repaired online, i.e. while the unit is in production and outside of major turnaround periods.