OCI Nitrogen: Risk Based Inspection implementation for asset integrity and operational reliability

Risk Based Inspection implementation for asset integrity and operational reliability

Our client, OCI Nitrogen, wanted to move from periodic inspections to a fully risk based approach for managing static equipment. PDM joined as an implementation and engineering partner, embedding Risk Based Inspection (RBI) into daily asset management practices. The result: improved insight into asset risks, fewer unplanned shutdowns and a scalable, data-driven inspection approach.

OUR CUSTOMER

OCI Nitrogen, a major chemical producer operating multiple ammonia plants at its Geleen site. Asset integrity and operational reliability are critical to ensuring safe, continuous production in a high-risk process environment.

THE CHALLENGE

Preventing unplanned shutdowns and production losses

Traditional time-based inspections provided limited insight into actual asset risks. OCI Nitrogen needed a more proactive way to manage the integrity of static equipment and prevent unexpected failures that could lead to downtime or incidents.

Transition from periodic to risk based inspections

Moving to Risk Based Inspection required more than a technical study. The challenge was to structurally embed risk-based thinking into existing asset management processes and inspection workflows, without disrupting operations.

Embedding RBI into the organization

To be effective, RBI had to become part of daily decision-making. This meant aligning different disciplines, creating a shared understanding of risks and degradation mechanisms, and ensuring the approach could be sustained over time.

Creating a scalable and future-proof approach

OCI wanted an RBI methodology that could be standardized and rolled out to other sites, requiring consistency, clarity and alignment with international standards.

Building excellence together

PDM worked closely with OCI Nitrogen as an implementation partner, designing and embedding a Risk Based Inspection program aligned with API 580.

We translated RBI requirements into a practical framework tailored to the ammonia production processes and asset portfolio. Through multidisciplinary workshops, we identified critical degradation mechanisms, assessed risks and translated these insights into optimized inspection strategies.

By integrating RBI vertically into existing processes, PDM ensured the methodology was not a one-off analysis, but a structural part of asset management and daily operations.

The impact we made

The Risk Based Inspection program provided OCI Nitrogen with clear, data-driven insight into asset integrity risks and enabled more focused inspection efforts.

Reduced risk of unplanned shutdowns and incidents
Earlier identification of critical failure mechanisms
Better-founded inspection decisions based on quantified risk
Increased control over asset integrity and operational reliability
A scalable RBI approach applicable to other OCI locations

Facing Similar challenges?

PDM supports asset-intensive organizations in implementing Risk Based Inspection as an integrated part of asset management, improving safety, reliability and performance.

OUR APPROACH in action

We don’t just advise on standards. We embed risk-based thinking into daily practice, combining technical depth with hands-on implementation to deliver lasting impact.

Risk Based Inspection with practical embedding:

From RBI framework design to integration into existing asset management processes and workflows.

API 580 aligned, tailored to your assets:

International best practices translated to fit specific processes, equipment and organizational context.

Multidisciplinary collaboration:

Workshops and alignment across engineering, inspection and operations to create shared ownership of risk.

Data-driven inspection strategies:

Inspection planning based on actual risk profiles instead of fixed intervals.

Scalable and sustainable solutions:

Designed for long-term use and rollout across multiple sites.

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