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KP4: Ageing and Life Extension Process Integrity Offshore Template

INSTALLATION or
DUTYHOLDER

Key Persons
interviewed

DATES(S)

Company

Summary of Inspection Traffic Lights

IMT and INSPECTOR(S)

Position

Red
6 5

Amber Green W
4 3 2 1 0

Section A: Ageing and Life Extension (ALE) Policy and Leadership


Section B: ALE - Organising
Section C: ALE - Planning and Implementing
Section D: ALE - Measuring Performance
Section E: ALE - Auditing and Reviewing
Performance
Summary of Inspection Findings:

HSE Action taken:

Rev. 2 01 November 2011

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KP4: Ageing and Life Extension Process Integrity Offshore Template

Section A: Ageing and Life Extension (ALE) - Policy

Section A: Ageing and Life Extension (ALE) - Policy


Onshore Management:

Rev. 2 01 November 2011

Page 2 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template


Offshore Operations:

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
5

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

Rev. 2 01 November 2011

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 3 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section B: ALE - Organising

Rev. 2 01 November 2011

Page 4 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section B: ALE - Organising


Onshore Management:

Offshore Operations:

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
5

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

Rev. 2 01 November 2011

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 5 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section C: ALE - Planning and Implementing


(Questions for offshore OIM, core crew, control room operators, production
operators, maintenance technicians, Independent Competent Persons, and
safety reps)
Principal Questions:
1) What do you consider the ageing and life extension issues to

be for process safety?


2) Can you give some examples where you have encountered
issues regarding ageing and life extension?
3) How did you deal with these?
4) Describe how it is ensured that:
a) the design basis for topsides plant and equipment is suitable for
current and projected production profiles, and fluid composition;
b) modifications to the process system are integrated with the existing
production operations;
c) performance standards for safety critical elements on existing (as
well as new) process systems are suitable and sufficient for the
revised functional specification;
d) improvements in health, safety, and welfare standards are
implemented where reasonably practicable in compliance with
current HSE and Industry guidance, and applicable national and
international standards and codes of practice;
e) the mechanical integrity of systems containing hazardous materials
is sound;
f) obsolescence of software and hardware systems for control and
instrumentation for existing systems are identified, and alternatives
sourced;
g) redundant equipment that represents significant congestion and
aggravated explosion damage, or barrier to emergency response are
removed where this is reasonably practicable;
h) failure of one or more prevention or mitigation measures does not
increase risk to the most exposed group of workers to intolerable
levels for continued production operations
5) How does age trigger the above processes
6) How is safety culture on ALE encouraged?
7) How are views on ALE communicated to and from the

workforce
8) How do you assure the competency of personnel involved in
the management, operation, inspection, and maintenance of
plant and equipment?
9) How is competence assured for contractors?
10) How do you document Operational Controls and
Maintenance Records

Rev. 2 01 November 2011

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KP4: Ageing and Life Extension Process Integrity Offshore Template


Section C: ALE - Planning and Implementing

Benchmarks sought in replies:

Awareness of original design life of plant and equipment

Awareness of internal and external corrosion, corrosion under


insulation/passive fire protection and erosion

Awareness of vibration issues leading to fatigue especially small


bore tubing

Knowledge of relevant changes in regulation, regulatory guidance,


industry guidance, international standards and codes of practice

Knowledge of relevant operational experience

Incident investigation and dissemination of findings

Incident reporting of near misses as well as RIDDOR and HCRs

Policy on ageing and life extension covering the projected lifetime


of the asset

Periodic review of design basis triggered by trends in production


profile, or time elapsed from previous review

Updated heat and material balances

Updated material selection guide

Key documentation P&IDs, Cause and Effect Diagrams, Hazardous


Area Classification Drawings, Operating Procedures etc. are
revised to reflect changes

Formal Safety Assessments, HAZID, HAZOP, Fault Tree Analysis,


Failure Modes and Effects Criticality Analysis triggered by policy on
ALE

Safety Integrity Levels are conducted/reviewed to confirm no


changes in functional, reliability/availability, or vulnerability
specifications

A continuing programme of non-destructive testing and visual


inspection methods is used to verify adequate wall thickness, and
absence of defects

A flexible hose register is maintained

A seeps, weeps, and leaks register is maintained

A defined life repair register is maintained, audited and reviewed

A log of inhibits and over-rides is maintained, audited, and


reviewed.

An operational risk assessment process is in place

Examples of leading (e.g. number of total PSVs successfully tested


in a period), and lagging (e.g. number of faults discovered during

Rev. 2 01 November 2011

Page 7 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template


Section C: ALE - Planning and Implementing
testing of PSVs) indicators provided

Formal safety assessment - Hazard and Operability Study/Hazard


Analysis, Failure Modes and Effects Criticality Analysis

Asset register of safety critical elements, Inherently Safer Design,


Risk Graph, Layers of Protection Analysis, Fault Tree Analysis

Risk Based Inspection, Campaign, Breakdown, Condition


Monitoring

Periodic replacement, testing and inspection

Operating and Maintenance records, including service life

Incident data, internal/external

Integrated system

Work packs, work orders, operating instructions, written schemes of


examination, maintenance routines, performance standards

Change requests, approvals, tracking register, management of


change procedures, verification

Procedures for changes in: plant and equipment safe operating


envelopes; plans, procedures and key documentation; people and
organisation; major accident hazards; regulatory policy; guidance,
and international codes and standards

Design life is documented

Key Performance Indicators are identified

An understanding of ageing issues

An understanding of life extension issues

Well defined roles and responsibilities

Wide consultation with the workforce

Ownership of the management system

Systems and procedures for change control

Arrangements to secure corporate memory

Systems and procedures for document control

Systems and procedures for Operation

Systems and procedures for Maintenance management

Competence assurance systems in place for operations and


maintenance personnel

Competence assessment system for contractors

Rev. 2 01 November 2011

Page 8 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section C: ALE - Planning and Implementing


Onshore Management:
N/A

Offshore Operations:
Loss of containment
Operational Risk Assessment
Process modifications/additions

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
5

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

Rev. 2 01 November 2011

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 9 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section D: ALE - Measuring Performance


(Questions for offshore OIM, core crew, control room operators, production
operators, maintenance technicians, Independent Competent Persons, and
safety reps)
Principal Questions:
1) What parameters are measured during
2)
3)
4)
5)

operation/inspection?
Where are the performance standards recorded?
How do you track progress for testing/inspection?
What are your key leading and lagging performance
indicators?
How are these communicated to senior management?

Benchmarks sought in replies:

Benchmarking of design against current standards

Inspection methods and techniques are used to detect ageing i.e.


creep, cracking, corrosion, damage, and wear

More detailed inspection required if life extension is contemplated


or deterioration from ageing is detected

Register of weeps, leaks, and breaks i.e. minor, significant and


major hydrocarbon releases to inform the life extension analysis

Data measurement which does not meet the performance


standards used to determine remaining or extension to life

Formal life-extension studies are performed

Use made of trends of incident, accident and near-miss data

Core Crew is aware of the status and condition of process plant and
equipment

Rev. 2 01 November 2011

Page 10 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section D: ALE - Measuring Performance


Onshore Management:
N/A

Offshore Operations:
Loss of containment
Operational Risk Assessment
Process modifications/additions

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
5

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

Rev. 2 01 November 2011

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 11 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section E: ALE - Auditing and Reviewing Performance


(Questions for senior management typically Asset Integrity Manager,
Maintenance Manager, Operations Manager, OIM, Process Engineering
Technical Authority)
Principal Questions:
1) How does the verification scheme address the ALE of

process plant & equipment (static & rotating) safety critical


elements (SCEs)?
2) Who conducts a review of key performance indicators?
3) How frequently?
4) What results from such a review?
Benchmarks sought in replies:

A degree of independence is included in the audit and review


arrangements

The outcome of audits and reviews results in an updated ageing


and life extension strategy

Proposed changes are recorded / logged assessed and approved


before implementation

Rev. 2 01 November 2011

Page 12 of 13

KP4: Ageing and Life Extension Process Integrity Offshore Template

Section E: ALE - Auditing and Reviewing Performance


Onshore Management:
N/A

Offshore Operations:
Loss of containment
Operational Risk Assessment
Process modifications/additions

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
5

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

Rev. 2 01 November 2011

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 13 of 13