Guidelines for Asset Integrity Management

List of Figures xi List of Tables xiii Preface xvii Acknowledgments xix Files on the Web xxi 1 Introduction 1 1.1 Background and Scope 1 1.2 What is Asset Integrity Management? 2 1.3 What Assets are Included? 5 1.4 AIM Life Cycle 7 1.5 Relationship to Other Programs 7 1.6 Relationship to RAGAGEP 8 1.7 Structure of this Document 12 Chapter 1 References 15 2 Management Responsibility 17 2.1 Leadership Roles and Responsibilities 17 2.2 Technical Assurance Responsibilities 25 Chapter 2 References 29 3 AIM Life Cycle 31 3.1 Overview 31 3.2 Research Through Process Development 33 3.3 Process Design 35 3.4 Engineering, Procurement and Construction 39 3.5 Commissioning 40 3.6 Operation and Maintenance 42 3.7 Decommissioning 44 3.8 RAGAGEP Selection and Application at Each Stage 45 Chapter 3 References 47 Appendix 3A. Design Review Suggestions 49 4 Failure Modes and Mechanisms 53 4.1 Introduction 53 4.2 Equipment Functions and Functional Failure 54 4.3 Failure Modes 57 4.4 Damage Mechanisms 61 4.5 Failure Effects 64 4.6 Risk 65 4.7 Analysis 66 4.8 ITPM Task Assignments 69 4.9 Operational Issues 69 4.10 Other Related Activities 70 Chapter 4 References 70 Appendix 4A. Risk Concepts Related to AIM 73 5 Asset Selection and Criticality Determination 77 5.1 Program Objectives and Philosophy 77 5.2 Asset Selection Criteria and Principles 79 5.3 Level of Detail 84 5.4 Asset Criticality Determination 86 5.5 Documentation 96 5.6 Roles and Responsibilities 97 Chapter 5 References 99 Appendix 5A. Sample Guidelines for Selecting Assets for an AIM Program 100 6 Inspection, Testing and Preventive Maintenance 105 6.1 ITPM Task Planning 107 6.2 ITPM Task Execution and Monitoring 128 6.3 ITPM Program Roles and Responsibilities 137 Chapter 6 References 141 Appendix 6A. Common Predictive Maintenance and Nondestructive Testing (NDT) Techniques for Mechanical Equipment 142 7 Established Approaches for Developing Test and Inspection Plans 171 7.1 Code/Standard Approaches 171 7.2 Regulatory Authority Approaches 172 7.3 Company-Specific Approaches 172 7.4 Risk-Based Inspection (RBI) 173 7.5 Failure Modes, Effects and Criticality Analysis Approaches 176 7.6 Safety Instrumented Systems 179 Chapter 7 References 184 8 AIM Training and Performance Assurance 187 8.1 Skills and Knowledge Assessment 189 8.2 Training For New and Current Workers 191 8.3 Verification and Documentation of Performance Assurance 193 8.4 Certifications 194 8.5 Ongoing and Refresher Training 195 8.6 Training for Maintenance Technicians and Operators Performing Maintenance Tasks 197 8.7 Training for Technical Personnel 200 8.8 Contractor Issues 202 8.9 Roles and Responsibilities 203 Chapter 8 References 206 Appendix 8A. Sample Training Survey 207 Appendix 8B. Sample Training Guide 208 9 Asset Integrity Procedures 211 9.1 Types of Procedures Supporting the AIM Program 213 9.2 Identification of Needs 216 9.3 Procedure Development Process 220 9.4 Format and Content 223 9.5 Other Sources of AIM Procedures 226 9.6 Implementing and Maintaining AIM Procedures 227 9.7 AIM Procedure Program Roles and Responsibilities 229 Chapter 9 References 229 Appendix 9A. Example AIM Procedure 232 10 Quality Management 239 10.1 Design 241 10.2 Procurement 243 10.3 Fabrication 244 10.4 Receiving 246 10.5 Storage and Retrieval 247 10.6 Construction and Installation 248 10.7 In-service Repairs, Alterations and Rerating 250 10.8 Temporary Installations and Temporary Repairs 252 10.9 Decommissioning / Re-use 254 10.10 Used Assets 255 10.11 Spare Parts 256 10.12 Contractor-Supplied Assets and Materials 256 10.13 QA Program Roles and Responsibilities 257 Chapter 10 References 257 Appendix 10A. Sample Vendor QA Plan 260 Appendix 10B. Positive Material Identification 262 Appendix 10C. Sample Service Contractor QA Plan 266 11 Equipment Deficiency Management 269 11.1 Equipment Deficiency Management Process 270 11.2 Acceptance Criteria 270 11.3 Equipment Deficiency Identification 274 11.4 Responding to Equipment Deficiencies 275 11.5 Equipment Deficiency Communication 278 11.6 Tracking of Temporary Repairs 279 11.7 Deficiency Management Roles and Responsibilities 279 Chapter 11 References 280 12 Equipment-Specific Integrity Management 287 12.1 Vessels, Tanks and Piping 289 12.2 Relief and Vent Systems 294 12.3 Instrumentation and Controls 297 12.4 Rotating Equipment 300 12.5 Fired Equipment 303 12.6 Electrical Systems 304 12.7 Fire Protection and Suppression Systems 305 12.8 Ventilation and Purge Systems 306 12.9 Protective Systems 307 12.10 Passive Mitigation Systems 309 12.11 Solids-Handling Systems 310 12.12 Refrigeration Systems 311 12.13 Utilities 311 12.14 Safety Equipment 311 Chapter 12 References 314 Appendix 12A. Asset Integrity Activities by Equipment Type 317 13 AIM Program Implementation 383 13.1 Budgeting and Resources 383 13.2 Use of Data Management Systems 396 13.3 AIM Benefits and Return on Investment 400 Chapter 13 References 402 Appendix 13A. AIM Program Design Activity Worksheets 403 14 Metrics, Audits and Continuous Improvement: Learning from Experience 409 14.1 Performance Measurement and Monitoring 411 14.2 AIM Program and Implementation Audits 420 14.3 Continuous Improvement 427 Chapter 14 References 429 Appendix 14A. AIM-Related Regulatory Citations 430 15 Other Asset Management Tools 437 15.1 Introduction to Common Risk-based Analytical Techniques Used in AIM Programs 437 15.2 Incorporating Risk into AIM Decisions 443 15.3 Reliability-Centered Maintenance 445 15.4 Protection Layer Analysis Techniques 448 15.5 Asset Failure and Root Cause Analyses 451 Chapter 15 References 457 Acronyms and Abbreviations 459 Glossary 463 Index 469