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.
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, multi-site organisations in implementing uniform asset management approaches that strengthen control and alignment, compliance and operational performance across locations.
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.
