Guidelines for Asset Integrity Management

CCPS (Center for Chemical Process Safety)(Autor*in)

Wiley-AIChE (Verlag)

Erschienen am 6. Januar 2017

496 Seiten

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This book is an update and expansion of topics covered inGuidelines for Mechanical Integrity Systems (2006). The newbook is consistent with Risk-Based Process Safety and Life Cycleapproaches and includes details on failure modes andmechanisms. Also, example testing an inspection programs isincluded for various types of equipment and systems. Guidance andexamples are provided for selecting and maintaining critical safetysystems.

Auflage

1. Auflage

Sprache

Englisch

Verlagsort

New York

USA

Verlagsgruppe

John Wiley & Sons

Produkt-Hinweis

Reflowable

Dateigröße

Dateigröße: 4,13 MB

Schlagworte

Process Safety training Arbeitssicherheit u. Umweltschutz i. d. Chemie Mechanical Failure Chemical and Environmental Health and Safety AIChE factory safety engineering safety Chemische Verfahrenstechnik Prozesssicherheit Maschinenbau process safety mechanical engineering chemical engineering chemistry Chemie Arbeitssicherheit mechanical integrity system failure

ISBN-13

978-1-119-36425-2 (9781119364252)

Schweitzer Klassifikation

Chemie Chemietechnik

Chemie Technische Chemie

Sachbuch / Ratgeber Technik / Naturwissenschaft Chemie

Technik / Architektur Chemietechnik

Thema Klassifikation

Technologie, Ingenieurswissenschaft, Landwirtschaft, Industrieprozesse Industrielle Chemie und Fertigungstechnologien Industrielle Chemie und Chemietechnologie

DNB DDC Sachgruppen

Naturwissenschaften Chemie

Technik

Technik Ingenieurwissenschaften und Maschinenbau

Technik Technische Chemie

Dewey Decimal Classfication (DDC)

Technology Management & public relations General management

BIC 2 Klassifikation

Mathematics & science Chemistry

Technology, engineering, agriculture Industrial chemistry & manufacturing technologies Industrial chemistry Chemical engineering

Technology, engineering, agriculture Mechanical engineering & materials

BISAC Klassifikation

Science Chemistry / General Industrial & Technical

Technology & Engineering Engineering (General)Chemical & Biochemical

Technology & Engineering Industrial Health & Safety

Warengruppensystematik 2.0

Naturwissenschaften, Medizin, Informatik, Technik Chemie

Andere Ausgaben

CCPS (Center for Chemical Process Safety)

Guidelines for Asset Integrity Management

Versand in 15-20 Tagen

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.

Intro
GUIDELINES FOR ASSET INTEGRITY MANAGEMENT
Contents
List of Figures
List of Tables
Preface
Acknowledgments
Files on the Web
1 Introduction
1.1 Background and Scope
1.2 What is Asset Integrity Management?
1.3 What Assets are Included?
1.4 AIM Life Cycle
1.5 Relationship to Other Programs
1.6 Relationship to RAGAGEP
1.7 Structure of this Document
Chapter 1 References
2 Management Responsibility
2.1 Leadership Roles and Responsibilities
2.1.1 Organizational Roles and Responsibilities
2.1.2 Roles and Responsibilities Matrix
2.1.3 Reporting and Communication Mechanisms
2.1.4 Managing Changes, Abnormal Situations and Incidents
2.1.5 Auditing
2.1.6 Management Review and Continuous Improvement
2.2 Technical Assurance Responsibilities
2.2.1 Defining Acceptance Criteria
2.2.2 Providing Technical Content
2.2.3 Establishing Metrics
2.2.4 Ensuring Technical Review
2.2.5 Incorporating New Knowledge
Chapter 2 References
3 AIM Life Cycle
3.1 Overview
3.2 Research Through Process Development
3.3 Process Design
3.4 Engineering, Procurement and Construction
3.5 Commissioning
3.6 Operation and Maintenance
3.7 Decommissioning
3.8 RAGAGEP Selection and Application at Each Stage
Chapter 3 References
Appendix 3A. Design Review Suggestions
4 Failure Modes and Mechanisms
4.1 Introduction
4.2 Equipment Functions and Functional Failure
4.2.1 Required Performance
4.2.2 Loss of Ability
4.2.3 Observed Performance: Revealed vs Unrevealed Failure
4.2.4 Failures vs Incipient Failures
4.2.5 Failures vs Deviations
4.2.6 Documentation of Functional Specifications
4.3 Failure Modes
4.3.1 Mechanical Failures vs Operational or Maintenance Errors
4.3.2 Common Cause Failure Identification
4.3.3 Fail-Safe Direction
4.3.4 Less-Common Failure Modes
4.3.5 Level of Detail for Failure Modes
4.4 Damage Mechanisms
4.5 Failure Effects
4.5.1 Effects of Unrevealed Failures
4.5.2 Effects of Revealed Failures
4.6 Risk
4.7 Analysis
4.8 ITPM Task Assignments
4.9 Operational Issues
4.10 Other Related Activities
Chapter 4 References
Appendix 4A. Risk Concepts Related to AIM
5 Asset Selection and Criticality Determination
5.1 Program Objectives and Philosophy
5.2 Asset Selection Criteria and Principles
5.3 Level of Detail
5.4 Asset Criticality Determination
5.4.1 Historical Background
5.4.2 Definitions
5.4.3 Why Determine Asset Criticality?
5.4.4 Criticality Analysis
5.4.5 Risk-Based Criticality
5.5 Documentation
5.6 Roles and Responsibilities
Chapter 5 References
Appendix 5A. Sample Guidelines for Selecting Assets for an AIM Program
6 Inspection, Testing and Preventive Maintenance
6.1 ITPM Task Planning
6.1.1 Select ITPM Tasks
6.1.2 Develop Sampling Criteria
6.1.3 Other ITPM Task Planning Considerations
6.1.4 Schedule ITPM Tasks
6.2 ITPM Task Execution and Monitoring
6.2.1 Document Asset and ITPM Task Results
6.2.2 Implement and Execute ITPM Tasks
6.2.3 Review and Act on ITPM Data and Findings
6.2.4 Manage the Task Schedule
6.2.5 Monitor the ITPM Program
6.3 ITPM Program Roles and Responsibilities
Chapter 6 References
Appendix 6A. Common Predictive Maintenance and Nondestructive Testing (NDT) Techniques for Mechanical Equipment
Appendix 6B. Imperfection vs Type of NDE Method
Appendix 6C. Common Codes and Standards
Appendix 6D. Summary of Selected Condition Monitoring Techniques
7 Established Approaches for Developing Test and Inspection Plans
7.1 Code/Standard Approaches
7.2 Regulatory Authority Approaches
7.3 Company-Specific Approaches
7.4 Risk-Based Inspection (RBI)
7.4.1 Benefit of Software Support for RBI
7.4.2 Differences from Conventional AIM Programs
7.4.3 RBI Flowchart
7.5 Failure Modes, Effects and Criticality Analysis Approaches
7.6 Safety Instrumented Systems
Chapter 7 References
8 AIM Training and Performance Assurance
8.1 Skills and Knowledge Assessment
8.2 Training For New and Current Workers
8.3 Verification and Documentation of Performance Assurance
8.4 Certifications
8.5 Ongoing and Refresher Training
8.6 Training for Maintenance Technicians and Operators Performing Maintenance Tasks
8.7 Training for Technical Personnel
8.8 Contractor Issues
8.9 Roles and Responsibilities
Chapter 8 References
Appendix 8A. Sample Training Survey
Appendix 8B. Sample Training Guide
9 Asset Integrity Procedures
9.1 Types of Procedures Supporting the AIM Program
9.2 Identification of Needs
9.3 Procedure Development Process
9.4 Format and Content
9.5 Other Sources of AIM Procedures
9.6 Implementing and Maintaining AIM Procedures
9.7 AIM Procedure Program Roles and Responsibilities
Chapter 9 References
Appendix 9A. Example AIM Procedure
10 Quality Management
10.1 Design
10.2 Procurement
10.3 Fabrication
10.4 Receiving
10.5 Storage and Retrieval
10.6 Construction and Installation
10.7 In-service Repairs, Alterations and Rerating
10.8 Temporary Installations and Temporary Repairs
10.9 Decommissioning / Re-use
10.10 Used Assets
10.11 Spare Parts
10.12 Contractor-Supplied Assets and Materials
10.13 QA Program Roles and Responsibilities
Chapter 10 References
Appendix 10A. Sample Vendor QA Plan
Appendix 10B. Positive Material Identification
Appendix 10C. Sample Service Contractor QA Plan
11 Equipment Deficiency Management
11.1 Equipment Deficiency Management Process
11.2 Acceptance Criteria
11.3 Equipment Deficiency Identification
11.4 Responding to Equipment Deficiencies
11.5 Equipment Deficiency Communication
11.6 Tracking of Temporary Repairs
11.7 Deficiency Management Roles and Responsibilities
Chapter 11 References
Appendix 11A. Fitness for Service
12 Equipment-Specific Integrity Management
12.1 Vessels, Tanks and Piping
12.2 Relief and Vent Systems
12.3 Instrumentation and Controls
12.4 Rotating Equipment
12.5 Fired Equipment
12.6 Electrical Systems
12.7 Fire Protection and Suppression Systems
12.8 Ventilation and Purge Systems
12.9 Protective Systems
12.10 Passive Mitigation Systems
12.11 Solids-Handling Systems
12.12 Refrigeration Systems
12.13 Utilities
12.14 Safety Equipment
Chapter 12 References
Appendix 12A. Asset Integrity Activities by Equipment Type
13 AIM Program Implementation
13.1 Budgeting and Resources
13.1.1 Program Development Resources
13.1.2 Initial Implementation Resources
13.1.3 Ongoing Efforts
13.2 Use of Data Management Systems
13.2.1 Computerized Maintenance Management
13.2.2 Inspection Data Management
13.2.3 Training Program Management
13.2.4 Document Management
13.2.5 Risk Management
13.3 AIM Benefits and Return on Investment
Chapter 13 References
Appendix 13A. AIM Program Design Activity Worksheets
14 Metrics, Audits and Continuous Improvement: Learning from Experience
14.1 Performance Measurement and Monitoring
14.1.1 Identify Appropriate Metrics
14.1.2 Collect and Analyze Performance Data
14.1.3 Monitor the Performance Measures and KPIs
14.2 AIM Program and Implementation Audits
14.3 Continuous Improvement
14.3.1 Incident Investigations
14.3.2 Asset Failure and Root Cause Analyses
Chapter 14 References
Appendix 14A. AIM-Related Regulatory Citations
15 Other Asset Management Tools
15.1 Introduction to Common Risk-based Analytical Techniques Used in AIM Programs
15.2 Incorporating Risk into AIM Decisions
15.3 Reliability-Centered Maintenance
15.4 Protection Layer Analysis Techniques
15.5 Asset Failure and Root Cause Analyses
15.5.1 Failure Analysis
15.5.2 Root Cause Analysis
Chapter 15 References
Acronyms and Abbreviations
Glossary
Index
EULA

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