Asset Integrity and Reliability (RBPS Element 10)
Risk based inspection, reliability centred maintenance, fitness for service and integrity operating windows that keep ageing assets fit for service and free of incidents
Asset Integrity and Reliability
(RBPS Element 10)
Asset Integrity is the lifecycle discipline that keeps pressure vessels, piping, rotating equipment, storage tanks, pipelines and safety critical instrumentation fit for service as they age. The element maps to OSHA 1910.119(j) and it brings together risk based inspection to API 580 and 581, reliability centred maintenance to SAE JA1011, fitness for service to API 579 1, damage mechanism cataloguing to API RP 571, integrity operating windows to API RP 584 and asset management to ISO 55001. The failure pattern is well documented and it runs to corrosion under insulation on insulated piping, high temperature hydrogen attack on hydrogen service steels, microbiologically influenced corrosion on water bottomed tanks and stress corrosion cracking in chloride and amine service. The element exists so that our team can detect and manage these mechanisms systematically before they cause a loss of containment.
How the study is executed
A structured, facilitated process that runs from scope definition through close out and produces defensible, actionable outputs.
We build an asset hierarchy to ISO 14224, score criticality on safety, environmental and production grounds and align it with the safety critical element register expected by the UK HSE.
Following API RP 571 we catalogue mechanisms such as thinning, high temperature hydrogen attack, hydrogen induced cracking, stress corrosion cracking, corrosion under insulation and microbial corrosion and map the corrosion loops against chemistry, temperature and velocity.
We build risk based inspection worksheets to API 580 and 581, a reliability centred maintenance failure mode analysis to SAE JA1011 and the resulting inspection and maintenance strategy.
We perform API 579 1 Level 1, 2 and 3 assessments, re rate the remaining strength factor and the maximum allowable working pressure and integrate the result with management of change and PHA revalidation.
Following API RP 584 we set critical, standard and informational windows, build DCS monitoring with an excursion workflow and a mechanical integrity engineering review.
We put in place an ISO 55001 aligned system with a KPI cascade, an annual self audit and a triennial third party audit, and the evidence needed for OSHA PSM mechanical integrity.
What the study covers in full
Outcomes of Asset Integrity and Reliability (RBPS Element 10)
- We manage corrosion under insulation, high temperature hydrogen attack, stress corrosion cracking and microbial corrosion
- We sustain pressure vessel integrity through the life of the asset
- We prevent excursions outside the integrity operating window
- We integrate the proof test programme for safety critical elements
- We give you a confident response on OSHA PSM (j) mechanical integrity
- We produce evidence that holds firm through an API 510, 570, 653, 580 and 579 1 review
- We align with PNGRB, the Indian Boiler Regulations and OISD STD 130 in India
- We satisfy ISO 55001 asset management
- We optimise inspection so that intervention drops by 30 to 50 percent
- We give you clarity on whether to run, repair or replace based on fitness for service
- We improve turnaround planning
- We reduce unplanned shutdown
- We help you avoid the cost of a loss of containment incident
- We optimise inspection cost
- We build a strong position with insurers through the integrity programme
- We extend asset life
Codes & standards we work to
Triggers that signal the need
Where Asset Integrity and Reliability (RBPS Element 10) applies
Wellheads, separators, gas compression, FPSO topsides, produced water systems.
Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.
Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.
Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.
Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.
Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.
Tangible deliverables
- An asset register with criticality ranking
- A damage mechanism catalogue to API RP 571
- A risk based inspection and reliability centred maintenance programme per asset
- Fitness for service assessments to API 579 1
- An integrity operating window register to API RP 584
- An asset integrity governance framework to ISO 55001
Ready to start your project?
Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.