Guidelines for Asset Integrity Management

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