Risk Based Inspection

Risk Based Inspection

The reliable and proven Risk Based Inspection (RBI) technology process developed by TCR Advanced, with guidance from API 580/581 and UK HSE, to provide industry with a good engineering practice.

rbiAiOM ® is a fully auditable and transparent software system calculates the risk profile of an item, based on its "active" and "potential" damage mechanism. The technology ensures that the resulting inspection interval for the item is reliably optimized in a safe and cost-effective manner. Operating limits are also defined by the RBI team to prevent an increase in damage rate or the initiation of a new damage mechanism. If business or safety risks are unacceptable, risk-mitigating options are also recommended as a part of the output. TCR’s RBI team study improves both, the team’s efficiency and knowledge sharing at the plant site along with enhancing communication across all departments. Additionally, it captures valuable plant knowledge from senior engineers in the team, encourages the training of junior engineers and augments corporate memory.

The technology is designed to facilitate the successful implementation of RBI technology processes at plant sites across oil and petrochemical industries, chemical, fertilizer and power plants. The technology causes an increase in plant availability, ensures cost saving, minimizes shutdowns, encourages changes in inspection strategies and intervals, and promotes improved safety compliance.

TCR Advanced has an experienced team of professionals that include Mechanical Engineers, Metallurgists, Corrosion Engineers, NDT Experts, RBI Experts, and Project Managers, that provide plants with RBI, Fitness-For-Service (API 579), Material Damage Mechanisms Assessment, Metallurgical Investigation & Failure Analysis, and In-service Inspection. The RBI team study, facilitated by TCR Advanced and rbiAiOM ® software platforms, helps all plant management and operations team to identify and resolve complex technical issues associated with static equipment including reactors, furnaces, strippers, distillation columns, heat exchangers, pressure vessels, reformers, boilers, fired heaters with associated items such as interconnected piping and storage tanks.


TCR's Risk-based approach to inspection provides immense benefits which include an increase in plant availability, cost saving, minimum shutdown durations, change in inspection strategies and intervals and improved safety compliance

Core Benefits of RBI

  • Increased Safety and Equipment Reliability
  • Fewer Planned Shutdowns
  • Fewer Unplanned Shutdowns
  • Longer Inspection Intervals
  • Reduction in Inspection Frequency and Maintenance Costs
  • Effectiveness Evaluation of Inspection Activities
  • Increased Consistency of Inspection Planning
  • Identification of Potential Damage Mechanisms
  • Prioritization of Inspection
  • Identification of Key Process Parameters affecting Degradation Rates
  • Assessment of Proposed Process Changes that could Impact Degradation Rates
  • Documentation of Current Plant Configuration And Materials of Construction
  • Improved Team Working And Communication between all Departments

Plant and equipments covered under TCR’s RBI technology process

  • All Types of Pressure Vessels including Reactors, Furnaces, Strippers, Absorbers, Distillation Columns, Heat Exchangers, Crackers, Crude Heaters and Other Fired Heaters, Reformers, Utility Power Boilers and Associated Equipment
  • Interconnected Piping between these Items Within The Plant Site
  • Over Ground and Buried Cross Country Fluid (Gas Or Liquid) Distribution Pipelines
  • All Types Of Storage Tanks

TCR's Continued Support for Plant Sites Includes:

  • RBI Technology Implementation Services
  • Total Asset Integrity Management Technology Support
  • Fitness-For-Service (API 579, BS 7910) and Remaining Life Assessments
  • Root Cause Material Damage Assessments, Metallurgical Investigation, and Failure Analysis
  • Training & Technology Transfer To In-House Engineers to Effectively Manage Plant Integrity

However, it must be recognized that apart from the reliability of the RBI technology process for delivering the set objectives and desired benefits, several other factors like the inclusion of best practices, the comprehensiveness of the team study method, the competence of the engineers involved at the plant site and the quality of the output contribute equally to the inspection.

The approach to

risk based inspection

is based on developing strong cooperation between the plant personnel and TCR PP SIMTECH experts. The adopted process of guided expert judgment is based on operational experiences and a strong technical basis for evaluation of possible degradation mechanisms. TCR believes that incorporation of these fundamental requirements in the evolution and development of the RBI technology process has made PP SIMTECH the global leader in this technology. Their distinctiveness differentiates them from the other players and their popularity is evident in the published testimonials from various clients.