Guidelines for Asset Integrity Management

,

• Publisher: Wiley-AIChE
• Year: 2017
• ISBN:
  9781119364252
• Edition: 1
• Topic: Scienze fisiche
• Subtopic: Chimica industriale e tecnica

This book is an update and expansion of topics covered in Guidelines for Mechanical Integrity Systems (2006). The new book is consistent with Risk-Based Process Safety and Life Cycle approaches and includes details on failure modes and mechanisms. Also, example testing an inspection programs is included for various types of equipment and systems. Guidance and examples are provided for selecting and maintaining critical safety systems.

1 Introduction

This chapter introduces asset integrity management (AIM), including the scope and objectives of AIM programs throughout a facility life cycle and the relationship of AIM to other process safety elements. The last section in this chapter outlines the structure of this document.

Since a successful AIM program involves leadership, managers, engineers, operating and maintenance personnel, contractors, suppliers and support staff, this document was prepared for a wide range of audiences and potential users. AIM is an integrated product of proper equipment, dependable human performance and effective management systems. Guidelines are given for developing, implementing and continually improving an AIM program that includes these areas of focus. Behind these focus areas needs to be an involved, supportive management. Consequently, this document also includes guidance to those supporting the program.

1.1 BACKGROUND AND SCOPE

For decades, AIM activities, in one form or another, have been a part of industry’s efforts to prevent incidents and maintain productivity. Industry initiatives, company initiatives and regulations in various countries have helped both to define AIM program requirements and to accelerate implementation of AIM programs. AIM is already ingrained in the culture of many process plants, as well as facilities in other related industries. AIM activities are essential for process facilities to maintain economic viability.

AIM has been a part of international process safety regulations for many years, including the Seveso Directive and its implementations in Europe (Reference 1-1) as well as Offshore Installation (Safety Case) regulations (Reference 1-2). Since 1992, a major incentive for process industries in the United States to implement AIM programs has been the Occupational Safety and Health Administration (OSHA) process safety management (PSM) standard, 29 CFR 1910.119 (Reference 1-3). This was followed by the Environmental Protection Agency (EPA) risk management program (RMP) rule, 40 CFR 68 (Reference 1-4). These performance-based regulations each contain a mechanical integrity (MI) element that defines the minimum requirements of a program through six subelements that address:

• Equipment to be maintained
• Written MI procedures
• MI training
• Inspection and testing
• Equipment deficiencies
• Quality assurance.

Specific requirements are not prescriptively stated in these regulations, but the sub-elements represent time-proven practices for an effective AIM program. The details of each sub-element are left to the discretion of the facility to develop and implement. All PSM- and RMP-covered U.S. facilities in operation since the regulations were issued have been required to audit compliance with these requirements at least every three years. Many of these audits reveal that companies continue to have significant opportunities to improve their AIM programs.

This document was written primarily for process industry facilities. However, most of the content applies to other industries as well. Although this document was written in the United States, a conscious effort has been made to keep the book applicable to facilities worldwide.

1.2 WHAT IS ASSET INTEGRITY MANAGEMENT?

For the purposes of this book, asset integrity management (AIM) is a management system for ensuring the integrity of assets throughout the life cycle of the assets. In this context, an asset is a process or facility that is involved in the use, storage, manufacturing, handling or transport of chemicals, or the equipment comprising such a process or facility. Examples of assets include off-shore and on-shore extraction and processing equipment; process and auxiliary tanks, vessels and piping systems including their internal components; control systems; safety systems; buildings and other structures; and transport containers. The selection of which assets are “important” is discussed in Section 1.3 and in Chapter 5.

AIM is a product of many activities, usually performed by many people. When these activities are done well, AIM can provide the foundation for a safe, reliable facility that minimizes threats to the workforce, the public and the environment. Effective AIM is also consistent with good business practices.

AIM programs vary according to industry, regulatory requirements, geography and plant culture. However, some characteristics appear to be common to effective AIM programs. For example, they:

• Include activities to ensure that assets are designed, procured, fabricated, installed, operated, inspected, tested and maintained in a manner appropriate for its intended application.
• Clearly designate assets to be included in the program based on defined criteria.
• Prioritize assets to help optimally allocate financial, staffing, storage space and other resources.
• Help plant staff perform planned maintenance and reduce the need for unplanned maintenance.
• Help plant staff recognize when equipment deficiencies occur and include...

Table of contents

• Cover
• Title Page
• Copyright
• Series Title Page
• List of Figures
• List of Tables
• Preface
• Acknowledgments
• Files on the Web
• 1 Introduction
• 2 Management Responsibility
• 3 AIM Life Cycle
• 4 Failure Modes and Mechanisms
• 5 Asset Selection and Criticality Determination
• 6 Inspection, Testing and Preventive Maintenance
• 7 Established Approaches for Developing Test and Inspection Plans
• 8 AIM Training and Performance Assurance
• 9 Asset Integrity Procedures
• 10 Quality Management
• 11 Equipment Deficiency Management
• 12 Equipment-Specific Integrity Management
• 13 AIM Program Implementation
• 14 Metrics, Audits and Continuous Improvement: Learning from Experience
• 15 Other Asset Management Tools
• Acronyms and Abbreviations
• Glossary
• Index
• Eula