25 marquee operators · 21 countries · verified roster
Bayer · Pfizer · TATA · Adani · JSW · ISRO · Siemens · Bosch · DuPont · Mahindra · Hindalco · and others
Risk-based inspection to API 580 and 581 · corrosion rates, remaining life and inspection intervals derived rather than assumed.
Fixed equipment degrades on a schedule the equipment sets, not the one in the inspection plan. We establish corrosion rates from measured thickness history, calculate remaining life against minimum required thickness, and rebuild inspection intervals around risk instead of calendar habit.
Because it allocates the same attention to a low-consequence utility line as to a high-temperature reactor circuit. A calendar plan spreads inspection effort evenly across a population that does not degrade evenly, so effort is spent opening equipment that was never going to fail while the aggressive damage mechanisms get the same interval as everything else.
Risk-based inspection reverses that. Probability of failure comes from the damage mechanisms actually credible for the material, service and temperature · thinning, stress corrosion cracking, high-temperature hydrogen attack, creep, fatigue, brittle fracture. Consequence comes from what is inside the equipment and what happens if it is released. The product decides both how often the item is inspected and, more importantly, what technique is used, because a general thickness survey will not find the cracking mechanism that is going to open the vessel.
The precondition is data. An RBI assessment on a population with no reliable thickness history produces a plan built on assumed corrosion rates, which is a calendar plan wearing different language.
API 580 and 581 methodology · corrosion rates from measured history · deliverables independently reviewed and signed by a Chartered Engineer. Routes to the Risk + Safety practice lead within 24 hours.
Fixed equipment and piping compiled into an assessed population and divided into corrosion circuits · groups of piping sharing material, service, temperature and therefore damage mechanism. Circuitisation is where most RBI programmes are won or lost, because a circuit drawn too broadly hides the one line that is thinning.
Credible damage mechanisms identified per circuit and per vessel from material, process fluid, temperature, and operating history · thinning, environmental cracking, high-temperature mechanisms, mechanical fatigue. This determines the inspection technique, since each mechanism is found by a different method and missed by the others.
Historical thickness measurement data reviewed, outliers and misplaced CMLs identified, and short-term and long-term corrosion rates calculated per circuit. Remaining life computed against minimum required thickness determined from the design code, not from the original nominal thickness.
Probability of failure derived from damage mechanism and remaining life; consequence of failure from inventory, fluid properties, and the affected area or business impact. Items ranked on the risk matrix so the inspection plan is prioritised against risk rather than against equipment number.
An inspection plan issued per item stating the technique, the coverage, the CML locations and the next due date, with the basis recorded. Intervals extended where risk justifies it and shortened where it does not, within the limits your inspection code permits, and the whole plan documented so it survives an audit and a change of inspector.
Assessments follow the recognised risk-based inspection and in-service inspection codes your regulator and insurer expect. Every deliverable independently reviewed and signed by a Chartered Engineer (CEng MIE India).
Three landmark engagements from our verified roster · quantified outcomes, no client names disclosed without written permission.
Corrosion circuits redrawn across a crude and vacuum unit where the existing circuitisation grouped dissimilar services together. Recalculated corrosion rates from measured history identified a small number of circuits with substantially shorter remaining life than the prevailing inspection plan assumed.
Above-ground storage tanks assessed for internal and external inspection due dates against measured shell and floor data, producing a sequenced programme that spread out-of-service work across years rather than clustering it into one shutdown window.
Risk ranking across a mixed fixed-equipment population allowed intervals to be extended on low-risk items and tightened on a smaller high-risk group, redistributing inspection effort without increasing the total.
Tell us your plant, region, and scope · a named Chartered Engineer responds within 24 hours.