Overview
At iFluids Engineering, we offer highly specialized Risk-Based Inspection (RBI) Services to help industries proactively manage the integrity and reliability of critical assets. Our RBI programs are built on globally recognized standards, primarily API 580 (Risk-Based Inspection) and API 581 (Risk-Based Inspection Technology), and are designed to prioritize inspection activities based on risk assessment rather than traditional fixed intervals. This approach enhances plant safety, optimizes maintenance costs, and extends the operational life of equipment. Our services are not templated or generic. Each engagement is tailor-made, leveraging technical rigor and real-world experience to address the unique operating conditions, failure histories, and material characteristics of our client’s assets.
Through a structured, data-driven, and software-integrated approach, our team delivers RBI programs that align with industry best practices, optimize inspection efforts, reduce downtime, and extend asset lifecycle.
Our RBI Service Framework
PFD Systemization
We begin the RBI lifecycle with thorough systemization based on Process Flow Diagrams (PFDs). This step involves grouping equipment into logical process systems based on similarities in operating conditions and functionality. It provides the foundation for loop-wise corrosion assessment and helps in developing inspection scopes aligned with process behavior.
P&ID Circuitization
Using detailed Piping and Instrumentation Diagrams (P&IDs), we carry out Circuitization to group equipment, piping and Storage tanks into inspection circuits. Each circuit is defined by the common material of construction (MOC), operating conditions, and potential damage mechanisms. This enables focused inspection planning and ensures traceability of data across the asset lifecycle.
Damage Mechanism Identification
Our certified corrosion experts evaluate each component for potential damage mechanisms, including high-temperature hydrogen attack (HTHA), stress corrosion cracking (SCC), sulfidation, erosion, and more. We use both empirical data and process conditions to assess susceptibility, ensuring alignment with API 571, API 580/581 and NACE standards.
CCD Preparation (API 970)
A Corrosion Control Document (CCD) is developed for an entire unit which includes detailed corrosion loop, documenting MOC, process data, operating envelope, expected damage mechanisms, and inspection methods. This is aligned with API 970 to serve as a master reference for ongoing RBI activities.
Integrity Operating Windows (API 584)
We define Integrity Operating Windows (IOWs) that outline the permissible process limits (e.g., temperature, pressure, pH, Limiting Corrosive components) to prevent damage mechanism activation. IOWs are linked to the CCD and monitored using client SCADA/DCS systems. Alerts are integrated with RBI platforms for continuous monitoring.
CML Optimization
We perform Condition Monitoring Location (CML) optimization based on damage potential, historical trends, and inspection effectiveness. The result is a focused set of TMLs (Thickness Monitoring Locations) that ensure complete coverage without redundancy—saving both time and cost while maintaining high reliability.
Semi-Quantitative PoF, CoF and Risk Ranking
Utilizing semi-quantitative methodologies, we determine the Probability of Failure (PoF) and Consequence of Failure (CoF) for each asset. These values are plotted in a Risk Matrix to prioritize inspection needs. This structured risk ranking forms the backbone of inspection planning and resource allocation.
Customized Inspection Strategy
Based on the criticality rankings and identified degradation threats, we develop tailor-made inspection strategies. These strategies define the inspection frequency, method of Inspection, and coverage area. Integration with plant shutdowns and reliability plans ensures zero conflict with production goals.
Historical Data Integration and Software Implementation
We migrate legacy data – Corrosion Data, inspection reports, past Thickness readings, all kind of Import templates and maintenance logs into the RBI software. Our expertise spans platforms such as:
- Cenosco
- Bently
- Meridium APM (GE)
We provide bulk uploads, data vetting, and auto-alert configuration for real-time integrity management and predictive analytics.
Inspection Effectiveness & Validation
Each inspection program is evaluated for effectiveness, ensuring that all identified damage mechanisms are adequately addressed. Post-implementation, we conduct validation workshops involving client operations, inspection, and maintenance teams to align on findings and inspection strategies.
RBI Software Evergreening
Our RBI programs are designed for evergreening, ensuring that risk models, inspection data, and equipment histories are continuously updated. We support periodic revalidation, inclusion of new failure modes, and integration of new equipment into existing RBI programs without disruption.
Our Technical Methodology – Structured, Certified, and Compliant
Every project at iFluids Engineering is executed by multi-disciplinary teams comprising:
- API 510 certified experts
- API 570 certified experts
- API 653 certified experts
- API 571 certified experts
- API 580 certified experts
- NACE Senior Corrosion Technologist
- NACE Corrosion Specialist
- Certified Welding Inspectors
We ensure
- Conversion of Historical Drawings: P&IDs, PFDs, Isometrics, and GADs are digitized into AutoCAD formats compatible with Asset Integrity Management System (AIMS).
- Optimized Thickness Measurement Location(TML) and Measurement Points: We follow the philosophies laid out in the MRPL/ONGC annexures, ensuring complete coverage without redundancy.
- Data Integrity and Migration: Upload of last two or more historical readings, vetting of data, and alignment with Software specified AIMS templates.
- Trend Analysis and Reporting: Graphical representation of wall thickness trends, alert thickness warnings, and predictive maintenance insights.
Industry Coverage
We bring our RBI and corrosion expertise to a diverse range of industries:
- Oil Refineries
- Petrochemical Units
- Gas Processing Plants
- Offshore and Onshore Hydrocarbon Facilities
- Power Generation Units and Utilities
- Chemical Plant
Why Choose iFluids Engineering?
- Certified personnel with API 510, API 570, API 571, API 580, and API 581 qualifications.
- Proven track record in implementing RBI across major refineries and petrochemical plants.
- Ability to integrate RBI programs seamlessly with existing maintenance management systems.
- Focused on delivering measurable risk reduction, inspection optimization, and lifecycle cost savings.