Guidelines for Asset Integrity Management

Since 1985, the Center for Chemical Process Safety (CCPS) has been the global leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 100 training modules through its Safety in Chemical Engineering Education (SACHE) series.

• List of Figures xiList of Tables xiiiPreface xviiAcknowledgments xixFiles on the Web xxi1 Introduction 11.1 Background and Scope 11.2 What is Asset Integrity Management? 21.3 What Assets are Included? 51.4 AIM Life Cycle 71.5 Relationship to Other Programs 71.6 Relationship to RAGAGEP 81.7 Structure of this Document 12Chapter 1 References 152 Management Responsibility 172.1 Leadership Roles and Responsibilities 172.2 Technical Assurance Responsibilities 25Chapter 2 References 293 AIM Life Cycle 313.1 Overview 313.2 Research Through Process Development 333.3 Process Design 353.4 Engineering, Procurement and Construction 393.5 Commissioning 403.6 Operation and Maintenance 423.7 Decommissioning 443.8 RAGAGEP Selection and Application at Each Stage 45Chapter 3 References 47Appendix 3A. Design Review Suggestions 494 Failure Modes and Mechanisms 534.1 Introduction 534.2 Equipment Functions and Functional Failure 544.3 Failure Modes 574.4 Damage Mechanisms 614.5 Failure Effects 644.6 Risk 654.7 Analysis 664.8 ITPM Task Assignments 694.9 Operational Issues 694.10 Other Related Activities 70Chapter 4 References 70Appendix 4A. Risk Concepts Related to AIM 735 Asset Selection and Criticality Determination 775.1 Program Objectives and Philosophy 775.2 Asset Selection Criteria and Principles 795.3 Level of Detail 845.4 Asset Criticality Determination 865.5 Documentation 965.6 Roles and Responsibilities 97Chapter 5 References 99Appendix 5A. Sample Guidelines for Selecting Assets for an AIM Program 1006 Inspection, Testing and Preventive Maintenance 1056.1 ITPM Task Planning 1076.2 ITPM Task Execution and Monitoring 1286.3 ITPM Program Roles and Responsibilities 137Chapter 6 References 141Appendix 6A. Common Predictive Maintenance and Nondestructive Testing (NDT) Techniques for Mechanical Equipment 1427 Established Approaches for Developing Test and Inspection Plans 1717.1 Code/Standard Approaches 1717.2 Regulatory Authority Approaches 1727.3 Company-Specific Approaches 1727.4 Risk-Based Inspection (RBI) 1737.5 Failure Modes, Effects and Criticality Analysis Approaches 1767.6 Safety Instrumented Systems 179Chapter 7 References 1848 AIM Training and Performance Assurance 1878.1 Skills and Knowledge Assessment 1898.2 Training For New and Current Workers 1918.3 Verification and Documentation of Performance Assurance 1938.4 Certifications 1948.5 Ongoing and Refresher Training 1958.6 Training for Maintenance Technicians and Operators Performing Maintenance Tasks 1978.7 Training for Technical Personnel 200Contents ix8.8 Contractor Issues 2028.9 Roles and Responsibilities 203Chapter 8 References 206Appendix 8A. Sample Training Survey 207Appendix 8B. Sample Training Guide 2089 Asset Integrity Procedures 2119.1 Types of Procedures Supporting the AIM Program 2139.2 Identification of Needs 2169.3 Procedure Development Process 2209.4 Format and Content 2239.5 Other Sources of AIM Procedures 2269.6 Implementing and Maintaining AIM Procedures 2279.7 AIM Procedure Program Roles and Responsibilities 229Chapter 9 References 229Appendix 9A. Example AIM Procedure 23210 Quality Management 23910.1 Design 24110.2 Procurement 24310.3 Fabrication 24410.4 Receiving 24610.5 Storage and Retrieval 24710.6 Construction and Installation 24810.7 In-service Repairs, Alterations and Rerating 25010.8 Temporary Installations and Temporary Repairs 25210.9 Decommissioning / Re-use 25410.10 Used Assets 25510.11 Spare Parts 25610.12 Contractor-Supplied Assets and Materials 25610.13 QA Program Roles and Responsibilities 257Chapter 10 References 257Appendix 10A. Sample Vendor QA Plan 260Appendix 10B. Positive Material Identification 262Appendix 10C. Sample Service Contractor QA Plan 26611 Equipment Deficiency Management 26911.1 Equipment Deficiency Management Process 27011.2 Acceptance Criteria 27011.3 Equipment Deficiency Identification 27411.4 Responding to Equipment Deficiencies 27511.5 Equipment Deficiency Communication 27811.6 Tracking of Temporary Repairs 27911.7 Deficiency Management Roles and Responsibilities 279Chapter 11 References 28012 Equipment-Specific Integrity Management 28712.1 Vessels, Tanks and Piping 28912.2 Relief and Vent Systems 29412.3 Instrumentation and Controls 29712.4 Rotating Equipment 30012.5 Fired Equipment 30312.6 Electrical Systems 30412.7 Fire Protection and Suppression Systems 30512.8 Ventilation and Purge Systems 30612.9 Protective Systems 30712.10 Passive Mitigation Systems 30912.11 Solids-Handling Systems 31012.12 Refrigeration Systems 31112.13 Utilities 31112.14 Safety Equipment 311Chapter 12 References 314Appendix 12A. Asset Integrity Activities by Equipment Type 31713 AIM Program Implementation 38313.1 Budgeting and Resources 38313.2 Use of Data Management Systems 39613.3 AIM Benefits and Return on Investment 400Chapter 13 References 402Appendix 13A. AIM Program Design Activity Worksheets 40314 Metrics, Audits and Continuous Improvement: Learning from Experience 40914.1 Performance Measurement and Monitoring 41114.2 AIM Program and Implementation Audits 42014.3 Continuous Improvement 427Chapter 14 References 429Appendix 14A. AIM-Related Regulatory Citations 43015 Other Asset Management Tools 43715.1 Introduction to Common Risk-based Analytical Techniques Used in AIM Programs 43715.2 Incorporating Risk into AIM Decisions 44315.3 Reliability-Centered Maintenance 44515.4 Protection Layer Analysis Techniques 44815.5 Asset Failure and Root Cause Analyses 451Chapter 15 References 457Acronyms and Abbreviations 459Glossary 463Index 469