🏭 Why Age Matters in RBI
Not all facilities are created equal. When it comes to Risk-Based Inspection (RBI), the age of the plant, condition of its assets, and availability of integrity data can drastically change the inspection strategy.
New facilities often start with limited inspection history but well-documented design and materials.
Older facilities may have legacy systems, undocumented changes, and decades of operation — with corrosion and wear already in progress.
With the right RBI software (like RBLX™), both scenarios can be managed effectively — but the approach must change.
🆕 RBI in New Facilities
New assets offer a clean slate — but that doesn’t mean they’re low-risk.
Key RBI Considerations:
- 🔍 Unknown initial corrosion behaviour
- 🧱 Limited inspection history
- 🧾 Manufacturer data must be trusted (for now)
- 📉 Design data available for estimating POF/COF
Strategy:
✅ Use API 581 models with conservative assumptions
✅ Define baseline corrosion loops
✅ Install corrosion monitoring devices early
✅ Set shorter initial inspection intervals, extend later based on findings
Role of RBLX™:
- Build the full equipment hierarchy from day one
- Link to CCD, IOWs, and design specs
- Establish corrosion loops and IOW alerts for each system
- Assign initial RBI plans with built-in templates
🏚️ RBI in Aging Facilities
Older plants present different challenges — and bigger opportunities for inspection savings and safety improvements.
Challenges:
- ⚠️ Hidden corrosion/damage mechanisms
- 📉 Incomplete inspection history
- 🧩 Material changes or undocumented repairs
- ❗ Higher POF due to cumulative wear and process variability
Strategy:
✅ Use actual wall thickness and historical inspection data
✅ Reassess every loop for updated mechanisms (API 571)
✅ Apply semi-quantitative or quantitative RBI
✅ Identify NII opportunities to reduce outage costs
Role of RBLX™:
- Import years of thickness and inspection data into RBLX-IDMS
- Flag overdue or high-risk items
- Visualize remaining life across circuits
- Recommend NII alternatives based on historical data and HOIS RP103 logic
🔍 Comparison Summary
| Feature/Concern | New Facility | Old Facility |
| History Available | Limited or none | Long but variable |
| Corrosion Known? | Not yet | Likely present |
| Initial Risk Bias | Conservative (data-light) | Reactive or evolving |
| Inspection Method | Default RBI intervals | Data-informed RBI + NII options |
| Role of RBLX™ | Build, track, grow | Integrate, optimize, evergreen |
💡 Real-World Takeaway
Whether your site is 30 weeks old or 30 years old, RBI is essential. But the path to reliability, safety, and cost efficiency must be tailored to:
- ⚙️ Equipment condition
- 🧪 Known damage mechanisms
- 📊 Data maturity
That’s where a flexible, standards-based platform like RBLX™ makes the difference.
📩 Have a new asset or old facility you want to optimize?
Request a demo: lteng.co.uk/contact
📧 Or email: info@lteng.co.uk
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