Expanded Risk Based Inspection - Corrosion Operating Windows

Abstract Mechanical Integrity (MI) systems based on OSHA 1910.119 guidelines have been critical to ensure safe and reliable operations of one of our large, corrosive manufacturing plant sites. The site started implementing a conventional MI system starting in 1995 and made steady progress, but soon started to get over whelmed with repeat inspections. In 2000 the plant implemented Risk Based Inspection (RBI) techniques which greatly helped manage the overall program. The Risk Based Inspection program has been highly successful but some surprise failures prompted us to expand our current RBI program to include inspection beyond just MI containment, improve the feedback on operational changes, improve the end of life process and generate corrosion operating windows for critical equipment. The process developed some unique ways to combine reliability Failure Mode and Effects Analysis (FMEA) with Risk Based Inspection techniques to expand beyond just looking at containment for fixed equipment. This paper goes over the process used to expand the existing RBI program and the results obtained.