RBI, RCM, FFS, IOW — keeping ageing assets fit-for-service and incident-free
Asset Integrity is the lifecycle discipline that keeps pressure vessels, piping, rotating equipment, storage tanks, pipelines, and safety-critical instrumentation fit for service through ageing. The element maps to OSHA 1910.119(j) and integrates API 580/581 RBI, SAE JA1011 RCM, API 579-1 FFS, API RP 571 damage mechanisms, API RP 584 IOW, and ISO 55001.
Asset integrity is where process safety meets the balance sheet. Sites that manage integrity proactively extend asset life, optimise inspection spend by 30-50%, and avoid the loss-of-containment events that dominate Tier 1 PSE statistics. Without it, ageing infrastructure becomes a latent liability and insurance becomes increasingly expensive.
Asset Integrity is the equipment-side complement to Operating Procedures (Element 8) — operations handles how the plant is run, AIM handles whether the plant is fit to be run. It feeds Process Knowledge (Element 6) the equipment data, integrates with MOC (Element 13), and provides the inspection record that Auditing (Element 19) verifies. Element 10 is one of the most heavily inspected elements during OSHA / MSIHC audits.
A focused 6-step methodology calibrated to deliver asset integrity & reliability as a working capability — not a documented compliance artefact.
Build hierarchy per ISO 14224; score criticality on safety / environmental / production; align with SCE register per UK HSE.
Per API RP 571 — thinning, HTHA, HIC, SCC, CUI, MIC; map corrosion loops with chemistry / temperature / velocity.
Build risk-based inspection worksheets per API 580/581; RCM FMEA per SAE JA1011; inspection / maintenance strategy.
API 579-1 Level 1/2/3 assessments; RSF / MAWP re-rating; MOC integration with PHA revalidation.
Per API RP 584 — critical / standard / informational windows; DCS monitoring with excursion workflow; MI engineering review.
ISO 55001-aligned system; KPI cascade; annual self-audit / triennial third-party; OSHA PSM MI evidence.
Decision-gated workflow showing the actual sequence of activities — from initiation through steady-state operation — with key decision points highlighted.
We can scope this element implementation against your facility, regulatory context, and existing management-system maturity — and integrate it with the other Risk Based Process Safety (RBPS) elements you already operate.