Abstract Pressures on cost reductions, and tougher environmental regulations are driving an upsurge in the application of risk management approaches to optimise the utilisation of plant assets. Risk based inspection (RBI), and fitness-for-service (FFS) assessments are key risk management approaches to assist in minimising the risk of loss, and in maintaining plant availability at reduced maintenance costs. In 1998 GASCO initiated the process of changing the traditional practice of inspection planning based only on probability of failure to the semi-probabilistic Risk Based Inspection planning method that uses a multi-disciplined team to identify the criticality of operating assets based on both the likelihood of failure, and the consequences of failure. This paper describes the successful experience of the implementation of Risk Based Inspection at GASCO Bab and BuHasa plants, and identifies the key success factors which led to clear technical benefits and savings of over one million dollars per year.