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KP4: Ageing and Life Extension Inspection Template Fire and Explosion

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:

August 2011 V1.0

Page 1 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section A: Ageing & Life Extension Policy and Leadership


(Questions for senior management typically Operations Manager, Asset
Integrity Manager, Safety Engineering Technical Authority)
Principal Questions:
1) What do you consider the ageing and life extension issues to be for

Fire, Explosion and Hazardous Fume (FEHF:DMP) detection, mitigation


and protective systems?
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 the policies that senior management has in place to ensure
that:
a) the design basis for FEHF:DMP equipment is suitable for current
and projected Major Accident Hazards (MAH);
b) modifications to the FEHF:DMP systems are competed with a full
consideration of the current MAH risk profile of an installation;
c) performance standards for safety critical elements on existing (as
well as new) FEHF:DMP equipment 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) redundant equipment that represents significant congestion and
aggravated explosion damage, or barrier to emergency response
are removed where this is reasonably practicable;
g) 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) What are the Key Performance Indicators used to indicate the asset

integrity status to Senior Managers?


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

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

August 2011 V1.0

Page 2 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion
Section A: Ageing & Life Extension Policy and Leadership
Policy on ageing and life extension covering the projected lifetime
of the asset

Periodic review of design basis triggered by trends in MAH profile,


or time elapsed from previous review

Updated consequence, vulnerability and probability models

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


Hazardous Area Classification Drawings, Operating Procedures
etc. are revised to reflect any 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 PFP condition,
thickness, and absence of defects

Registers 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 successful TR integrity,


detectors and Active fire protection systems tested in a period),
and lagging (e.g. number of faults discovered during testing of Fire
pumps, detectors, PFP, fire walls and penetrations HVAC systems)
indicators provided

Ageing and life extension (ALE) policy owned by senior


management
Senior management has responsibility for implementing ALE policy
Senior management support for equipment/system replacement
Asset Integrity Management (AIM) addresses ALE
Fitness for purpose demonstrations are described
References to codes, standards & guidance, for example:
o OSD Info sheets 1/2006, 2/2006, 3/2006 4/2009 BS 13702, IP
15 SPC 30
o HSE Research Report RR 509 Plant Ageing (Management of
equipment containing hazardous fluids or pressure)
o Relevant Energy Institute publications

August 2011 V1.0

Page 3 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section A: Ageing & Life Extension Policy and Leadership


Onshore Management:

Offshore Operations:

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served

August 2011 V1.0

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 4 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section B: Ageing & Life Organisation


(Questions for senior management typically Operations Manager, Asset
Integrity Manager, Safety Engineering Technical Authority)
Principal Questions:
1) Who is responsible for:

a) Major Accident Hazard identification and risk assessment;


b) The fire & explosion ALE policy;
c) Conducting fire & explosion integrity condition assessments and
life-extension studies etc. for the fire & explosion integrity system

2)
3)
4)
5)

6)

d) Maintenance and Testing of safety critical: detection, control


/mitigation and protective systems;
e) Operational Risk Assessment;
f) Management of Change;
How do these persons fit into the organization?
How are views on risk management, including downgraded situations
involving SCEs communicated to and from the workforce?
How do you document Operational Controls and Maintenance Records
How do you assure the competency of personnel involved in the
management, operation, inspection, and maintenance of plant and
equipment?
How is competence assured for contractors?

Benchmarks sought in replies:

An understanding of thee need for monitoring & trending data

An understanding of life extension issues for fire & blast resistance

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

August 2011 V1.0

Page 5 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section B: Ageing & Life Organisation


Onshore Management:

Offshore Operations:

HSE Comments:

HSE Action taken:

August 2011 V1.0

Page 6 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section C: Ageing & Life Extension Planning and Implementation


(Questions for senior management typically Safety Engineering Technical
Authority, Asset Integrity Managers, EH & S Managers, Project Managers,
OIMs)
Principal Questions:
What is your system for hazard identification?
How do you assess risk?
How do you establish the protective and mitigation measures?
How do you prioritise the work?
Is maintenance, inspection, or testing contracted out?
How is implementation controlled?
How is change controlled?
How are downgraded SCEs for fire, explosion and hazardous fume
managed
9) How is performance of the SCEs monitored and trended such that age
and condition trigger the above processes
1)
2)
3)
4)
5)
6)
7)
8)

Benchmarks sought in replies:

Risk Based Inspection, Campaign, Breakdown, Condition


Monitoring

Periodic replacement, testing and inspection

Operating and Maintenance records, including service life

Incident data, internal/external

Risk targets

Integrated system

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

Explanation of how equipment subject to ageing is selected and


identified
Review of the suitability of the performance standards
Evaluation of wear, deterioration and damage in service
Review for operation outside of design limits, and for changed
design standards
Obsolescence identified and managed
Plans for replacement and provision of spares
Targeted inspection and maintenance, including difficult to access
equipment

August 2011 V1.0

Page 7 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion
Section C: Ageing & Life Extension Planning and Implementation

Life extension studies and fitness for purpose demonstrations


available
Condition of mitigation systems such as PFP, gas detection or
deluge in place established
The original design criteria and any information that demonstrates
that the original design criteria are no longer valid available
Platform modifications, additions, any repairs / strengthening
particularly of the TR documented;
Changes of use violating the original design or previous integrity
assessment assessed;
Departures from the original basis of design e.g. increased gas
inventory or higher throughput in separators assessed and
actioned;
The versions of the codes used dispersion or explosion models
suitable and validated regularly

Firewater pump or main ring main failure resulting in overall deluge


failure evaluated and action planned

corrosion/blast wall integrity compromise detector obsolescence


considered and monitored/ action planned .

August 2011 V1.0

Page 8 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section C: Ageing & Life Extension Planning and Implementation


Onshore Management:

Offshore Operations:

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served

August 2011 V1.0

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 9 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section D: Ageing & Life Extension Measuring Performance


(Questions for senior management typically Safety Engineering Technical
Authority, Maintenance Managers, Production Supervisors)
Principal Questions:
1. What codes, standards, recommended practices, guidelines, etc.
have been identified as relevant to ageing & life-extension (ALE) and
asset integrity management (AIM) for fire explosion and hazardous
fume MAHs?
2. What specific key performance indicators (KPIs), 'traffic lights' or
similar are used to review the fire & explosion condition with
respect to ageing and the effectiveness of the maintenance, testing
and inspection system?
3. What inspection methods are used to detect ageing or deteriorating
performance of the FEDMS? How does the inspection philosophy
allow for the detection of ageing, e.g.
4. Planning and frequency of inspections and maintenance in
recognition of ageing mechanisms, including integration of
baseline, periodic and special inspections
5. Use of maintenance procedures which consider the need for a more
detailed inspection if a period of life extension is to be justified or
deterioration from ageing mechanisms is detected
6. Consideration of scheduling of IMR interventions in light of
deterioration rates, availability of competent services, reliability of
techniques and confidence for near- and long-term assurance of
integrity
7. What risk-based methods are employed that allow for loss of
integrity from ageing of detection and mitigation systems (with key
supporting references).
8. What leading or lagging indicators are used to indicate
components / structure or equipment that may not be performing as
required or showing signs of deterioration in their integrity or
performance?
9. What reference is made to codes, standards, recommended
practices, guidelines, etc., relevant to ageing & life-extension (ALE)
and fire & explosion integrity management?
10. How does the duty holder evaluate the implications of revised or
new codes, standards, guidelines, etc., and adapt fire & explosion
inspection and maintenance, etc., where necessary?
11. What parameters are measured during operation/inspection/ fault
condition?
12. Where are the performance standards recorded?
13. How do you track progress for testing/inspection?
14. How are these communicated to senior management?

August 2011 V1.0

Page 10 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion
Section D: Ageing & Life Extension Measuring Performance

Benchmarks sought in replies:

Leading and lagging KPIs to monitor impact of ALE are defined


Management reviews KPIs and acts
Contractor and 3rd party maintenance findings reviewed
Procedures in place to detect ageing
Ageing processes monitored
Failure trends identified
Benchmarking of design against current standards

Inspection methods and techniques are used to detect and trend


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

Senior Management is aware of the status and condition of plant


and equipment related to Fire, Explosion and Toxic Fume
management

August 2011 V1.0

Page 11 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section D: Ageing & Life Extension Measuring Performance


Onshore Management:

Offshore Operations:

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served

August 2011 V1.0

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 12 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section E: Ageing & Life Extension Auditing and Reviewing Performance


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

2)
3)
4)
5)

and hazardous fume detection control, mitigation and protective


system safety critical elements (SCEs)?
Who conducts a review of the key performance indicators?
How frequently?
What results from such a review?
How are recommendations to senior management made with respect
to the level of resources required to maintain fire & explosion integrity?

6) How are lessons learned and trended for incident, accident and near-

miss data and how is this being used to improve and the AIM system?
7) Are performance standards on the loss of integrity from deterioration

associated with ageing and life extension available for all fire &
explosion detection and mitigation systems safety critical elements
(SCEs)?
8) To what extent has the verification process identified any deterioration

from ageing mechanisms and associated loss of integrity or


demonstrated that integrity has not been compromised by ageing
mechanisms?
9) What evidence is there that fire & explosion SCEs meet / do not meet

performance standards? What anomalies have been identified?


10) What improvements have been identified and implemented as a result

of the verification process? How is their implementation monitored?


11) How has the senior management satisfied itself that the verification

process has adequately addressed any loss of integrity associated with


ALE?
12) What conclusions can be drawn directly from the verification process

on the risks from ALE to the overall fire & explosion integrity of the
installation?
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

Formal audit programme which addresses ALE management

August 2011 V1.0

Page 13 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion
Section E: Ageing & Life Extension Auditing and Reviewing Performance
processes
Audit findings reviewed by senior management
Management improvements identified
SCE verification process addresses ALE issues

August 2011 V1.0

Page 14 of 15

KP4: Ageing and Life Extension Inspection Template Fire and Explosion

Section E: Ageing & Life Extension Auditing and Reviewing


Performance
Onshore Management:

Offshore Operations:

HSE Comments:

HSE Action taken:

Traffic Light Score


SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6

SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served

August 2011 V1.0

GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4

PARTIAL
COMPLIANCE

GENERAL
COMPLIANCE

GENERAL
COMPLIANCE

Letter

Verbal advice

No findings

NOT
INSPECTED

Page 15 of 15