Asset Integrity

EJADA This project is funded by the EU

EJADA This project is funded by the EU
INTRODUCTION
For organisations that operate power plants, refineries, chemical plants,
utilities/ civil infrastructure and manufacturing sites, maintaining and
protecting the operational integrity of their facilities and equipment is a
high priority in delivering their product to consumers and clients.

A better understanding of the problems associated with trying to operate a

successful Asset Integrity Management system can go a long way to making
the whole industry safer and environmentally friendlier.

EJADA This project is funded by the EU

ASSET INTEGRITY

Asset Integrity can be defined as the ability of an asset to perform its

required function effectively and efficiently whilst protecting health,
safety and the environment.

EJADA This project is funded by the EU

ASSET INTEGRITY
What Is It?

The asset integrity element is the systematic implementation of activities,

such as inspections and tests necessary to ensure that important equipment
will be suitable for its intended application throughout its life. Specifically,
work activities related to this element focus on:

(1) Preventing a catastrophic release of a hazardous material or a sudden

release of energy;
(2) Ensuring high availability (or dependability) of critical safety or utility
systems that prevent or mitigate the effects of these types of events. 

EJADA This project is funded by the EU

ASSET INTEGRITY
Why Is It Important?

Designing and maintaining equipment that it is fit for its purpose and functions
when needed is of paramount importance to process industries. Maintaining
containment of hazardous materials and ensuring that safety systems work
when needed are two of the primary responsibilities of any facility.

EJADA This project is funded by the EU

ASSET INTEGRITY
Where/When Is It Done?
Asset integrity activities range from technical meetings involving experts
seeking to advance the state-of-the art in equipment design, inspection,
testing, or reliability, to a plant operator on routine rounds spotting leaks,
unusual noises or odors, or detecting other abnormal conditions. However,
this element primarily involves:
(1) Inspections, Tests, Preventive Maintenance, Predictive Maintenance,
and Repair Activities that are performed by maintenance and
contractor personnel at operating facilities
(2) Quality Assurance Processes, including procedures and training, that
underpin these activities. Asset integrity element activities occur at
many places and extend throughout the life of the facility.

EJADA This project is funded by the EU

ASSET INTEGRITY
Who Does it?
Asset integrity activities occur at several organizational levels. Industry
sponsored technical committees and organizations are continuously
working to advance the state of knowledge regarding proper:
 Design;
 Inspection, Test, and Preventive Maintenance (ITPM) practices to help
ensure that equipment is fit for service at commissioning, and remains
fit for service throughout its life.

Companies often establish corporate standards, and promote efforts to

continuously improve the safety and reliability of process equipment.
At an operating facility, the asset integrity element activities are an
integral part of day-to-day operation involving operators,
maintenance employees, inspectors, contractors, engineers, and others
involved in designing, specifying, installing, operating, or maintaining
equipment.
EJADA This project is funded by the EU
ASSET INTEGRITY
An example of test methods is the NDT, the six most
common NDT methods are:

1. Visual Testing (VT)

2. Radiography Testing (RT)
3. Ultrasonic Testing (UT)
4. Magnetic Particle Testing (MT)
5. Liquid Penetrant Testing (PT)
6. Eddy Current Testing (ECT)

EJADA This project is funded by the EU

ASSET INTEGRITY
What Are the Anticipated Work Products?
Asset integrity element work products include:
 Reports and data from initial inspections, tests, and other activities to
verify that equipment is fabricated and installed in accordance with
design specifications and is fit for service at startup.

 Results from ongoing ITPM tasks, performed by trained or certified

personnel and based on written procedures that conform to generally
accepted standards, that help ensure that equipment remains fit
for service.

 Controlled repairs and adjustments to equipment by trained personnel

using appropriate written procedures and instructions.

EJADA This project is funded by the EU

ASSET INTEGRITY
What Are the Anticipated Work Products?

 A system to control maintenance work, repair parts, and maintenance

materials needed for the work to help ensure that equipment remains fit
for service.

 A quality assurance program that helps prevent equipment failures that

could result from:

(1) Use of faulty parts/materials or

(2) Improper fabrication, installation, or repair methods (e.g., improperly

supporting the engine as discussed at the start of this chapter).

EJADA This project is funded by the EU

ASSET INTEGRITY
The primary objective of the asset integrity element is to help ensure
reliable performance of equipment designed to contain, prevent, or
mitigate the consequences of a release of hazardous materials or
energy. Although proper execution of work activities associated with this
element requires a high level of human performance, the ultimate work
product for this element is reliable and predictable equipment operation. 

EJADA This project is funded by the EU

ASSET INTEGRITY
How Is It Done?
An effective asset integrity program depends on management ensuring that:
 Equipment and systems are properly designed, fabricated, and installed.

 The unit is operated within the design limits of the equipment.

 ITPM tasks are conducted by trained and qualified individuals using

approved procedures and completed as scheduled.

 Repair work conforms to design codes, engineering standards, and

manufacturer’s recommendations.

 Appropriate actions are taken to address deficiencies, regardless of how

they are discovered.

EJADA This project is funded by the EU

ASSET INTEGRITY
Under the operational phase of the life cycle, the asset integrity, for
example in the oil and gas industry can be divided into disciplines
based on equipment categories:

 Static equipment integrity

 Rotating equipment/machinery integrity
 Electrical equipment integrity
 Instrument and control equipment integrity
 Structural integrity
 Pipeline integrity
 Well integrity
 Evacuation and rescue system integrity

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT

Asset Integrity Management is the means of ensuring that the people,

systems, processes and resources that deliver integrity are in place, in
use and will perform when required over the whole lifecycle of the asset.

Asset Integrity Management can further be described as the continuous

assessment process applied throughout design, construction, installation
and operations to assure that the facilities are and remain to be fit for
purpose.

Asset Integrity management improves plant reliability and safety whilst

reducing unplanned maintenance and repair costs.

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT

The integrity management process covers the Equipment containing the

fluid, the structures that support the equipment, and those other systems
that prevent, detect, control or mitigate, against a major accident hazard.
A loss of integrity (containment) could have an adverse impact on the safety
of personnel, on the safety of the asset / facilities, on the environment or
on production and revenue.

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
Structural Integrity Management
 Program Development
• Prescriptive
• Risk-based

 Execution
• In-serve inspection
• Data Management
• Anomaly Identification & Tracking

 Analysis
• Anomaly Resolution
• Weight Control
• Stability Analysis
• Life Extension

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
Mechanical Integrity

 Planning

• Criticality Assessments
• Planning & Scheduling
• Spare Parts Program

 Execution Phase

• Preventative Maintenance
• Predictive Maintenance
• Reliability Optimization

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT

Control System Integrity

• Software Quality Engineering

• Software Verification & Validation
• Cybersecurity

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
The Aim of the asset integrity management process is to provide a framework
for the following:
 Compliance with company standards, regulatory and legislative requirements;

 Assurance of technical integrity by the application of risk based or risk

informed engineering principles and techniques

 Delivery of the required safety, environmental and operational performance

 Retention of the license to operate

 Optimization of the activities and the resources required to operate the

facilities whilst maintaining system integrity

 Assurance of the facilities “Fitness” for purpose.

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
Key components:

• Design, fabricate and install all facilities and equipment in accordance with
applicable industry codes and recognised best practices.

• Operate facilities and equipment within design tolerances and within the
safe operating envelope.

• Routinely inspect and maintain equipment in accordance with industry

codes and recognised practices, including manufacturer recommendations
where appropriate.

• Analyse equipment failures to determine their cause.

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
Key components:

• Conduct all related tasks using trained and qualified individuals who
use approved procedure and complete the tasks as scheduled.
• Use high quality parts and materials, including a system for
positive material identification (PMI).
• Maintain an equipment archive with up to date equipment history.
• Safely dismantle and dispose of the facility at the end of its life cycle.
A systematic implementation of the above will help in preventing
accidents.

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
Some of the contributing factors to the assurance of current and continued
asset integrity are represented in the following figure.

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT

Once the scope of the asset integrity management (AIM) program has been
defined, AIM program efforts often focus next on developing and
implementing an inspection, Testing and Preventive Maintenance (ITPM)
program. ITPM might cut across more than one part of an organization. For
example, an Inspection Department may perform inspections and tests while
the maintenance Department carries out preventive maintenance tasks.

In many respects, the ITPM program is the core of AIM. However, inspections
and tests do not solve asset integrity problems; they can only help identify
and implement maintenance tasks needed to ensure the ongoing integrity of
AIM assets, in order to adequately control process risks.

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
Term Definition
Inspection Assessing the current condition and/or rate of
degradation of assets
Testing Checking the operation/functionality of assets. Includes
proof tests, which are the exercising of passive (standby)
systems.
Preventive Maintenance that seeks to reduce the frequency and
Maintenance severity of unplanned shutdowns by establishing a fixed
schedule of routine inspection and repairs
Inspection, Testing Scheduled proactive maintenance activities intended to:
and preventive 1. Assess the current condition and/or rate of
Maintenance (ITPM) degradation of assets,
2. Test the operation/functionality of assets,
3. Prevent asset failure by restoring asset condition

EJADA This project is funded by the EU

ASSET INTEGRITY MANAGEMENT
ITPM program development and implementation are divided into two major
phases:

1. ITPM Task Planning: The activities of this phase include identifying and
documenting the ITPM tasks needed to ensure ongoing integrity of AIM
program assets, establishing the frequency at which the ITPM tasks are
to be performed and translating the tasks into a schedule.
2. ITPM Task Execution and Monitoring: The plan becomes reality when the
tasks are executed by qualified personnel as scheduled. To help achieve
this objective, the ITPM program needs to ensure that processes are
established to monitor the schedule, the task results, and overall
program performance. In addition, continuous monitoring of the task
schedule and results provides a means for optimizing the tasks. ITPM
task execution does not stop at performing ITPM tasks. It includes issuing
corrective actions and tracking them to completion. Performing
inspections and tests by themselves is of little value; they only bring
value as a tool to correct deficiencies and to plan future maintenance
activities.
EJADA This project is funded by the EU
RISK BASED INSPECTION (RBI)
What is RBI?

• RBI is a method for using Risk as a basis for prioritising and managing the
efforts of an inspection program.
• In an operating plant, a relatively large percentage of the risk is associated
with a small percentage of equipment items.
• These potential high-risk components can require greater attention through
a revised inspection plan
• RBI permits the shift of Inspection & Maintenance resources to provide a
higher level of coverage on the high risk items and an appropriate effort on
lower risk equipment.

EJADA This project is funded by the EU

RISK BASED INSPECTION (RBI)
RBI assessment process works by identifying the consequences and the
likelihood of failure. Once identified these consequences and likelihoods
can provide a basic risk based ranking functionality to determine the
frequency of examination for topside and subsea process and piping
systems. This includes a qualitative analysis that allows for the prioritizing
of the pressure systems within a five by five matrix, which rates them
from lower to higher risk, which in turn can be used to identify high risk
areas that may require further risk analysis. Before starting any RBI
assessment there are certain things that need to be in place.

EJADA This project is funded by the EU

RISK BASED INSPECTION (RBI)
RBI output: The RBI provides information on using risk analysis to
develop an effective inspection plan.

The inspection plan include:

• Inspection Methods
• Extent of Inspection
• Inspection Interval
• Risk Mitigation
• Residual Risk

EJADA This project is funded by the EU

RISK BASED INSPECTION (RBI)
Equipment Covered
• Pressure Vessels—All pressure containing components.
• Process Piping—Pipe and piping components.
• Storage Tanks—Atmospheric and pressurized.
• Rotating Equipment—Pressure containing components.
• Boilers and Heaters—Pressurized components.
• Heat exchangers (shells, floating heads, channels, and bundles).
• Pressure-relief devices.

EJADA This project is funded by the EU

RISK BASED INSPECTION (RBI)
What Is Risk?

Risk is the combination of the probability of some event occurring

during a time period of interest and the consequences, (generally
negative) associated with the event. In mathematical terms.

EJADA This project is funded by the EU

RISK BASED INSPECTION (RBI)
Risk analysis

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RISK BASED INSPECTION (RBI)
Risk Matrix

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RISK BASED INSPECTION (RBI)
RBI Planning Process

EJADA This project is funded by the EU