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Guidelines for Asset Integrity Management

ISBN: 978-1-119-01014-2
496 pages
November 2016
Guidelines for Asset Integrity Management (1119010144) cover image

Description

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.  

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Table of Contents

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

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Author Information

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.

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