1echnlcal lnLearlLv Culdance noLe / 2010 aae 1

1echn|ca| Gu|dance Note

1echn|ca| Integr|ty Assurance rogramme (1IA)

Why th|s short note?


As parL of CCMAP (ConLrol of Ma[or AccldenL Pazard) 8eporL or SafeLv Case, SafeLv CrlLlcal LlemenLs
(SCLs) need Lo be ldenLlfled Lhrouah 81A (8ow 1le Analvsls), as parL of PLM (Pazard & LffecLs
ManaaemenL rocess). 8uL Lhe lmplemenLaLlon of MAP manaaemenL proaramme ls noL clearlv
undersLood clearlv bv all concerned.

As lndlcaLed above, Lhere are several confuslons (llsLed below) exlsLlna wlLhln hazardous lndusLrles on
manaalna Ma[or AccldenL Pazards (MAPs), as parL of AsseL lnLearlLv assurance process.

1. MAP ldenLlflcaLlon Lhrouah 81A, SCL deflnlLlon & ldenLlflcaLlon and relevance of performance
sLandards are noL undersLood bv malnLenance & operaLlon Leams ln Lhe rlahL perspecLlve,
2. no clear undersLandlna of whaL AsseL lnLearlLv (Al) reallv means and Lhe scope llmlLs of a
Lvplcal AlM proaramme. 1he lnablllLv Lo puL LoaeLher a 'do-able', cusLomlzed AlM proaramme
for Lhe operaLlna companv saLlsfvlna appllcable sLandards and codes LhaL wlll ulLlmaLelv resulL
ln effecLlve lnLernal sLake-holder 'buv-ln',
3. 8elaLlonshlps beLween rocess SafeLv ManaaemenL (SM), AsseL lnLearlLv ManaaemenL (AlM)
and PSLMS (PSL ManaaemenL svsLem),
4. 1he scope llmlLs for Al Lerms ueslan lnLearlLv, 1echnlcal lnLearlLv and CperaLlons lnLearlLv are
noL clearlv undersLood and lnLearaLed lnLo varlous relaLed svsLems wlLhln Lhe operaLlna
companv,
3. lnLerface lssues are noL clearlv deflned wlLh PSL, ro[ecLs, 8ellablllLv, lnspecLlon,
Lnalneerlna/ueslan, CperaLlons, MalnLenance resulLs ln a confused 8ACl Lhus dlluLlna/delavlna
Lhe varlous Al efforLs,
6. Al Leam Lvplcallv conslsLs of lnspecLlon enalneers buL AlM lncludes much more Lhan [usL
lnspecLlon of sLaLlc equlpmenL,
7. All Lhe kev elemenLs of Al are noL clearlv undersLood, deflned, lmplemenLed and Lracked,
8. 1he varlous rlsk/PSL Lerms relaLed Lo Al are noL undersLood ln Lhe rlahL perspecLlve, and
9. CompeLencv requlremenL of Al Leam members ls noL ldenLlfled, assessed and Lracked ln a clear
& comprehenslve manner.

ln Lhls shorL noLe prepared for AsseL lnLearlLv manaaers, Lhe auLhor aLLempLs Lo clear some of Lhe
common confuslons surroundlna AsseL lnLearlLv Assurance ManaaemenL (AlAM) process. lease be
remlnded LhaL Lhls shorL noLe can onlv alve some kev lnslahLs lnLo Lhe complex 1lA process and ls noL
lnLended Lo provlde compleLe auldance.




1echnlcal lnLearlLv Culdance noLe / 2010 aae 2

What |s Asset Integr|ty?

AsseL lnLearlLv ManaaemenL proaramme should be capable Lo malnLaln an asseL ln a llL-lor-Servlce (llS)
CondlLlon ln Lhe safesL, mosL rellable and cosL-effecLlve manner. ln oLher words, Lhe aoal of asseL
manaaemenL proaramme ls Lo effecLlvelv manaae corporaLe asseLs bv manaalna poLenLlal Ma[or AccldenL
Pazards (prevenL/conLrol/proLecL/mlLlaaLe/rescue). An ldeal AsseL lnLearlLv ManaaemenL proaramme
lncorporaLes deslan, malnLenance, lnspecLlon, process, operaLlons, and manaaemenL concepLs, slnce all
Lhese dlsclpllnes lmpacL Lhe lnLearlLv of lnfrasLrucLure and equlpmenL ln llne wlLh appllcable reaulaLlons
and companv Al pollcv.

ldeallv AlM should conslsL of 3 kev elemenLs such as:

1. ueslan lnLearlLv (ul):
a. uevelop ul performance sLandards ln llne wlLh appllcable companv
sLandards/lnLernaLlonal sLandards / lndusLrv besL pracLlces,
b. lncorporaLe Lhe ul assurance requlremenLs (for ConcepLual, lLLu, LC phases) lnLo
asseL deslan and LC / pro[ecL scope
c. Lnsure ul assurance bv wav of lnLernal audlLs, PSL8 (ro[ecL PSL 8evlew) and
verlflcaLlon, and
d. ueflne clear 8ACl for ul proaramme lnvolvlna PSL, ro[ecLs and CperaLlons.

2. 1echnlcal lnLearlLv (1l):
a. 1echnlcal lnLearlLv ls achleved when all Lhe hardware barrlers/SCLs are ln place wlLhouL
anv flaws or holes ln llne wlLh Lhe performance sLandard requlremenLs,
b. Cnce SCLs are ldenLlfled Lo Laa level and caLeaorlzed lnLo appllcable barrler aroups Lhen
Lhe asseL malnLenance pracLlces needs Lo be allaned wlLh performance sLandard
requlremenLs, and
c. 1l should be lnLernallv and exLernallv verlfled.

3. CperaLlons lnLearlLv (Cl):
a. When Lhe operaLlna envelopes are malnLalned ln all respecLs, Cl ls aLLalned,
b. 1vplcal Cl proaramme could lnclude aspecLs such as ManaaemenL of Chanae, Alarm
ManaaemenL, ShlfL-Pand Cver, CrlLlcal process conLrol overrldes, eLc.

1IA Imp|ementat|on-ke|ated Issues:

A 8ACl (8esponslble-AccounLable-ConsulLed-lnformed) for deparLmenLs llke PSL, Al, and 8ellablllLv ls verv
essenLlal for Lhe effecLlve dellverv of Al proaram and wlll ulLlmaLelv help Lo avold common confuslons
LhaL prevall ln Lhe lndusLrv. Loalcallv, Al ls parL of rocess SafeLv ManaaemenL (mechanlcal lnLearlLv ls one
of Lhe 14 CSPA MS elemenLs) and process safeLv manaaemenL should slL wlLhln companv PSLMS. 1he
PSLMS should be deflned ln such a manner LhaL occupaLlonal safeLv ls clearlv dlfferenLlaLed ln all respecLs
from process safeLv. Whlle assurance of ul & Cl should be [olnLlv ensured bv Al & PSL, Al should be
responslble for 1lA.

1echnlcal lnLearlLv Culdance noLe / 2010 aae 3

AsseL lnLearlLv and rellablllLv (SlL/ll, 8CM, eLc.) are closelv relaLed and compllmenL each oLher. lL ls a
common lndusLrv pracLlce Lo use SafeLv lnLearlLv Levels Lo ldenLlfv SCLs. ln summarv, asseL lnLearlLv can
be lmproved bv followlna varlous rellablllLv assessmenL Lechnlques (vlbraLlon monlLorlna, Lhermal
lmaalna, laser allanmenL, plpe Lhlckness LesLs, eLc).

Pavlna lnspecLlon enalneers ln Al Leam ls from Lhe loalc LhaL lnspecLlon of hvdrocarbon equlpmenL can
prevenL Loss of ConLalnmenL (malnlv due Lo corroslon) leadlna Lo MAP. 1hls ls Lrue Lo an exLenL. 8uL
looklna aL AsseL lnLearlLv ManaaemenL (AlM) from a hollsLlc perspecLlve, AlM ls much more Lhan mere
lnspecLlon, buL we all do reallze LhaL lnspecLlon can do prevenL LCC cases and hence MAPs. Al Leam
should conslsL of speclallsLs who undersLand AlM ln Lhe rlahL hollsLlc perspecLlve.

1echn|ca| Integr|ty Assurance rogramme (1IA):

Whlle ul & Cl are raLher self-explanaLorv, 1lA requlre furLher auldance for effecLlve lmplemenLaLlon and
hence elaboraLed furLher here. 1he kev 1lA process sLeps are provlded below:

re-8equlslLe 1: ldenLlfv barrlers /SCLs for Lhe asseL Lhrouah 81A afLer conslderlna all poLenLlal
MAPs up Lo unlL level. ConslderaLlon of Plah level /aenerlc MAPs such as llre, Lxploslon, and
1oxlc release wlll resulL ln confuslons whlle asslanlna SCL sLaLus Lo operaLlonal asseL Laas.
MAPs are consequence drlven and probablllLv should noL be consldered whlle ldenLlfvlna
MAPs uslna 8AM (8lsk AssessmenL MaLrlx). 1vplcallv buslness crlLlcal aspecLs are noL
consldered whlle ldenLlfvlna SCLs.

re-8equlslLe 2: 8ased on Lhe CCMAP / SafeLv Case SCL realsLer, S.M.A.8.1 (Speclflc-
Measurable-ALLalnable-8elevanL-1raceable) CperaLe-hase performance sLandards should be
developed for all ldenLlfled SCLs ln llne wlLh companv sLandards, lnLernaLlonal sLandards and
alobal besL pracLlces. Cnce Lhls ls developed, seek aareemenL from relevanL enalneerlna
auLhorlLles for Lechnlcal concurrence.

re-8equlslLe 3: CeL Lhe asseL realsLer cleaned-up for compleLeness & correcLness. 1vplcallv
Laas for vendor packaaes (llare, Compressor, chemlcal ln[ecLlon, power aeneraLors, eLc.) are
mlssed ouL (LoLallv or parLlallv) ln Lhe asseL realsLer or are lncluded noL adherlna Lo sLandard
Laaalna nomenclaLure. lL ls also a common flaw Lo flnd LhaL decommlssloned Laas are parL of
asseL realsLer.

re-8equlslLe 4: 8efore launchlna 1lA, lL ls recommended Lo have a focused 2 dav Lralnlna
proaramme Lo brlef all concerned on Lhe backaround, scope, ob[ecLlves, speclflc 1lA pro[ecL
requlremenLs, expecLed ouLcome, 1lA-8ACl and pro[ecL compleLlon requlremenL. lL wlll be a
aood ldea Lo lnclude an effecLlve shorL sesslon on 'Chanae ManaaemenL'.

re-8equlslLe 3: lorm Lhe 1lA pro[ecL Leam lnvolvlna resources boLh lnLernallv and exLernallv.

8ased on Lhe ldenLlfled SCLs, Lhe Laas ln Lhe asseL realsLer needs Lo be arouped Lo each of Lhe
SCL caLeaorles. 1he loalcal sLep Lo achleve Lhls ls Lo ldenLlfv sub-svsLems for each of Lhe SCLs
wlLh a clear focus on ldenLlfled MAPs. 1hls ls obvlouslv a verv laborlous process and should
1echnlcal lnLearlLv Culdance noLe / 2010 aae 4

lnvolve speclallsLs. 1here could be mulLlple SCL aroups LhaL requlre Lo be asslaned for one Laa
(for example, a flammable aas deLecLor locaLed ln hazardous area wlll requlre Lwo SCL
caLeaorles Lo be asslaned - l&C ueLecLlon and lanlLlon ConLrol). 1he efforLs requlred/
welahLaae for Lhls kev sLep ln Lhe 1lA process ls around 60-70.
o Note. 1lAl teom composltloo ooJ competeocv ls oootbet oteo wblcb wlll be JlscosseJ lo
tbe oext 1ecbolcol ColJooce Note ftom tbe ootbot.

now, Lhe nexL loalcal sLep ls Lo allan Lhe malnLenance plans / proaramme needs Lo be allaned
wlLh performance sLandard assurance requlremenLs ln CMMS (CompuLerlzed MalnLenance
ManaaemenL SvsLem). 1hls complex Lask ls crlLlcal and needs lnvolvemenL and co-operaLlon all
dlsclpllne heads. AddlLlonal exLernal compeLenL resources mav be requlred Lo compleLe Lhe
1lA pro[ecL, dependlna on Lhe avallablllLv of companv resources.
o Note. A 1lAl oolJe ls ooJet Jevelopmeot bv tbe ootbot to ptovlJe complete step bv step
oolJooce to complete tbls complex kev step.

Cnce Lhe above sLep ls compleLed, dependlna on Lhe companv Al kl requlremenLs (M
backloas, SCL acLlvaLlon on demand, SCL LesL resulLs, eLc.), dvnamlc lnLearlLv sLaLus (AllS) can
be aeneraLed from Lhe cusLomlzed CMMS. ldenLlfv a [udlclous mlx of S.M.A.8.1 lead & laa Al
kls ln aareemenL wlLh lnLernal sLake holders. Whlle developlna AllS, due credlL should be
consldered for conLlnaencv measures Laken bv planL for SCL fallure /anomalv condlLlons.

o Al or rocess SafeLv kl references:
rocess SafeLv Leadlna & Laaalna MeLrlcs -?ou do noL lmprove whaL vou do
noL measure" Alcb ccl5
ueveloplna rocess SafeLv lndlcaLors uk n5 n5C 254
AsseL lnLearlLv kev erformance lndlcaLors OCl
Culdance on ueveloplna SafeLv erformance lndlcaLors Ocu
rocess SafeLv erformance lndlcaLors for reflnlna & peLrochemlcal lndusLrles
All kl 754

Conc|us|on:

lmplemenLaLlon of 1lA ls verv perLlnenL Lo anv hazardous lndusLrv as parL of Lhelr CCMAP
demonsLraLlon efforL. Successful and effecLlve 1lA lmplemenLaLlon wlll requlre [olnL efforLs from all
lnLernal sLake holders wlLh Lhe Lop manaaemenL supporL and ls cerLalnlv 'doable' wlLh clear auldance of
an experL.

Author:

lllal Sree[lLh
plllal_sree[lLhhoLmall.com