Kp4 Template Process Integrity

Traffic Light Inspection Template

KP4: Ageing and Life Extension Process Integrity Offshore Template

INSTALLATION or DUTYHOLDERDATES(S)IMT and INSPECTOR(S)

Key Persons interviewed

Company

Position

Summary of Inspection Traffic LightsRedAmberGreenW

6543210

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:

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

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

Onshore Management:

Offshore Operations:

HSE Comments:

HSE Action taken:

Traffic Light Score

SERIOUS

NON-COMPLIANCESIGNIFICANT NON-COMPLIANCEGENERAL

NON-COMPLIANCEPARTIAL COMPLIANCEGENERAL COMPLIANCEGENERAL COMPLIANCENOT INSPECTED

Court proceedings recommended

6Enforcement Notice Served

5Letter & changes made to intervention

4 Letter

3Verbal advice

2No findings

10



Onshore Management:


HSE Comments:

HSE Action taken:

Traffic Light Score

SERIOUS






4 Letter

3Verbal advice

2No findings

10


(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 operations5) How does age trigger the above processes6) 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 RecordsBenchmarks 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 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


Onshore Management:

N/A


Loss of containment

Operational Risk Assessment

Process modifications/additions

HSE Comments:

HSE Action taken:

Traffic Light Score

SERIOUS






4 Letter

3Verbal advice

2No findings

10


(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 operation/inspection?

2) Where are the performance standards recorded?

3) How do you track progress for testing/inspection?

4) What are your key leading and lagging performance indicators?5) 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


Onshore Management:

N/A

Offshore Operations:Loss of containment

Operational Risk Assessment


HSE Comments:

HSE Action taken:

Traffic Light Score

SERIOUS






4 Letter

3Verbal advice

2No findings

10


(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


Onshore Management:

N/A


Loss of containmentOperational Risk Assessment


HSE Comments:

HSE Action taken:

Traffic Light Score

SERIOUS






4 Letter

3Verbal advice

2No findings

10

Rev. 2 01 November 2011

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Kp4 Template Process Integrity

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