API 580 and 581 Compliant RBI Solutions for a Major Middle Eastern Refinery

Project Background

Penspen was awarded a 3-year contract by a leading National Refining Company in the Middle East to conduct a Risk-Based Inspection (RBI) assessment and implementation in one Asset Performance Management (APM) software for one of the largest refineries in the world for its refining process & utilities units. In line with API 580 and 581 standards and GE-APM Meridium, the project aimed to enhance operational efficiency by transitioning from traditional time-based inspections to a more effective risk-based approach.

To address challenges related to operation, design, and inspection planning, Penspen implemented RBI and TM (Thickness Monitoring) modules  in APM Meridium which involves an extensive data-gathering process. This included integrating inspection activities into the Meridium platform which allows automating data interfacing with Systems, Applications, and Products in Data Processing (SAP).

Services

Penspen’s Asset Integrity team in the Middle East and Africa has been leading this project since 2022, addressing challenges such as data quality and the integration of existing data into new GE-APM Meridium software. The work process included:

• Task Optimisation: Designing specialised tools for marking drawings and automating repetitive tasks using VBA Macros to enhance efficiency and accuracy.
• APM Meridium Software Expertise: While progressing and delivering this project, Penspen working team has gained extensive expertise in handling implementation activities in APM Meridium which has included training from GE.
• Corrosion Loop Development: Identifying and mapping risk areas for proactive monitoring and management based on damage mechanisms.
• Damage Mechanism Identification: Conducting detailed analyses to identify potential corrosion and mechanical failure risks, allowing for timely interventions.
• Piping Circuit Creation: Establishing the asset groups for better inspection planning and management. Corrosion Monitoring Location (CML) Marking: Designating monitoring locations on inspection drawings to optimize the locations on the assets which may compromise asset integrity and proactively the asset to fail.  and streamline inspections.
• APM Template Population: Completing essential templates for accurate RBI analysis and reporting.
• RBI Analysis and Recommendations: Performing in-depth assessments that provide actionable insights to optimise inspection intervals of the refinery process units.

Result

With the project on track for completion in 2025, Penspen has significantly enhanced the client’s asset integrity management processes. We have closed critical data gaps and delivered high-quality results that streamline operations, reduce downtime, and increase production efficiency.

Commenting on the project, Arun Behl, Head of Sales & Marketing – East Region said: “The RBI (Risk-Based Inspection) project with this client is highly complex and demanding. Penspen has demonstrated its capabilities by not only managing the intricacies involved but also delivering high-quality results. This project is a testament to our team’s expertise in handling large-scale data collection and aligning it with industry-leading platforms such as GE Meridium. The successful execution of this project has further positioned Penspen as a trusted partner in the region, and we are now well-equipped to take on even more challenging projects of this nature.

At Penspen, we believe that RBI projects, like the one we have just delivered, are pivotal in driving the future of asset integrity management. As more companies embrace digitisation and automation, the demand for sophisticated, data-driven solutions like RBI will continue to grow. Penspen is fully prepared to support our clients in this transition, ensuring they can achieve higher levels of operational excellence, safety, and sustainability.”