Evaluation of Asset Integrity Management System (AIMS) : Guide
Evaluation of Asset Integrity Management System (AIMS) : Guide
Evaluation of Asset Integrity Management System (AIMS) : Guide
NRS 13 36 77
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Foreword....................................................................................................................... iv
3 Guidance.................................................................................................................20
Introduction................................................................................................................................................. 20
1. Fitness for purpose (FFP) graph............................................................................................................... 20
2. Risk-based inspection (RBI) wheel........................................................................................................... 22
3. RBI flowchart......................................................................................................................................... 23
1 Frequently asked questions
The information provided below is for guidance only, and is not a substitute for reading the relevant occupational health and
safety legislation for petroleum operations in Western Australia.
• safeguarding the safety and health of persons engaged in an operation, other protected persons, and the environment
by
–– i n an emergency, to an extent as specified in the safety management system of an operation, or as well as could
reasonably be expected in an emergency situation.
The related management activities ensure that the people, systems, processes, procedures, resources and plans to deliver
integrity are in place, in use, and fit for purpose over the whole lifecycle of the asset.
• several pages in Schedule 1 of the Petroleum Pipelines Act 1969 and Petroleum and Geothermal Energy Resources Act
1967, and Schedule 5 of the Petroleum (Submerged Lands) Act 1982 regarding operator, employer, obligations, duties,
and responsibilities acknowledgement (e.g. policy statement)
• the systems and procedures to be employed (e.g. permit to work or PTW, safety operating procedures or SOPs,
document control)
• the performance and ongoing maintenance of the systems and procedures initiated (e.g. audits, reviews, key
performance indicators or KPIs, technical change management)
• identification of hazards (e.g. PTW, job hazard safety analysis or JHSA, risk assessment)
• inspection, testing and maintenance (e.g. inspection, maintenance and repair or IMR; corrosion maintenance inspection
or CMI; safety critical function test or SCFT)
• tasks that may reasonably be given (i.e. AIM manager job description form or JDF)
• persons to authorise and supervise work (e.g. PTW, JHSA, SOPs and policies)
Note: In some instances, other sections within the case for safety will have already dealt with these subjects. For example,
the policy integrity statement may be a separate policy solely addressing integrity, but usually the company’s occupational
safety and health policy statement will suffice. The same applies to PTW, SOPs and JHSAs, which may be covered in the
case for safety section detailing a “system for the safe performance of work”.
QQ. The level of documentation required to cover integrity appears to be quite substantial. What do I need to
provide in an SMS submission for acceptance by the Minister?
AA. The level of documentation detailed in an SMS should be appropriate for the size, scope, complexity, and level of risk for an
operation. For integrity, this may range from a few paragraphs for small operations with a low level of risk, through to several
pages for large, complex facilities or operations with a much higher level of risk.
QQ. Using examples of components or considerations relating to asset integrity management , when would a
paragraph or two on integrity suffice as opposed to several pages in a case for safety?
A1. A paragraph or two
In a simple low-risk operation, an asset register is created and populated on a simple electronic maintenance management
system (MMS) covering all assets of the operation or facility. Using a pressure vessel as an example, the vessel’s details
are recorded in the asset register, its inspection frequency and type are established in accordance with Australian Standard
AS/NZS 3788:2006 Pressure equipment – In-service inspection (the hazard rating determines the inspection intervals for
internal and external inspections if and when required) and this information is entered into the MMS.
When the vessel is close to the inspection date, the system “flags” the vessel with a work order and inspection SOPs and/or
checklists and procedures are generated. The tasks are then carried out according to the system for the safe performance
of work (PTW, JHSA, SOPs and policy), with a record of the subsequent findings, repairs, corrosion rates and other outcomes
retained in electronic and/or hard copy format once the vessel is found to satisfy FFP requirements and returned to service.
The next inspection date is entered into the MMS.
Large-scale operations of far greater complexity may have several plans that fall under the AIMS, and therefore require a
brief summary of each plan, and its respective components where applicable.
Components that might be considered when determining an appropriate AIMS are listed below.
Note: Some of the items have the same intent but have acquired different names and acronyms during industry use.
Methodologies
Overview
Considerations
• lighting
• water
• fuel supply
• power
• communications
• fire protection, suppression and detection
• office and control rooms
• processing, storage and handling areas
6 Policy leadership, commitment and strategy
6.1 General
6.1.1 There is a documented policy with strategic
objectives for managing the integrity of the facility
that:
Introduction
The three guidance diagrams included here are not suitable for all industrial applications, operations, and facilities. Care should
be exercised in their use as they are only provided for guidance on the basic principles of integrity or fitness for purpose and
risk-based inspection.
DESIGN
INSTALLATION
DECOMMISSIONING
OBSOLESCENCE
COMMISSIONING
EXTENSION OR
DESIGN LIFE
PLANNED
ose
for purp
Decreasing Fi tness Increasing
failure frequency failure frequency
Before commissioning or start-up of the pressure vessel in the plant, plans should be formulated for corrosion and inspection
management, inspection maintenance and repair, systems, procedures and practices. The strategy adopted for corrosion
management and inspection of the pressure vessel is likely initially to be a planned maintenance schedule determined by
Australian Standards, moving to a risk-based inspection (RBI) schedule once sufficient operational data are available to
support the decision-making process.
• The vessel walls will have undergone baseline ultrasonic testing (UT), with documented results.
• Quality assurance or quality control (QA /QC) design and/or fabrication flaws (if any) will have been detected and repaired.
• Non-destructive test (NDT) results will have been established for corrosion rate calculations.
• The suitability of design and materials for operational conditions will have been confirmed (refer to sections 4.4.3 and
4.4.4.1 of AS/NZS 3788:2006 for guidance).
• Design excursions (e.g. levels above and below design pressures, temperature, sweet to sour transition) and operational
history will have been established.
The inspection frequencies determined at the project inception and/or design reappraisal stages may need to be increased
when:
• the remaining life assessment is conducted following completion of 60 per cent of the design life. Where no design life
is evident, refer to section 5.1 of AS/NZS 3788:2006 for guidance (e.g. 100,000 operating hours or second inspection
interval)
• the failure or repair rates increase
• the vessel sustains damage.
Note: Wastage rates are considered to be the controlling factor in pressure vessel life expectancy, and may be determined from
UT readings over a period of time (refer to section 4.4.4.2 of AS/NZS 3788:2006 for guidance).
To extend the design life of the pressure vessel, additional measures may be required in the form of additional safety
equipment, procedures, practices, inspections, monitoring, testing, revisions of recommended practices and standards, and
analysis and calculation of the rates of corrosion, fatigue, creep and hydrogen attack if the vessel is re-lifed.
At some point, a finite asset life is achieved when the key performance indicators (e.g. frequency of failure at inspection, number
of repairs, wastage) reach levels that are considered to be intolerable, with associated risks and hazards not being as low as
reasonably practicable (ALARP). The asset is then decommissioned.
BACK
FEED
RIS
KA
11.
SS
Feedback 1. Review
ES
2.
SM
10. Design
ENT
Verification reappraisal
3.
9. Define Development
RIS K M
8. Statement 4. RBI
7. 5. matrices
ON
ANA
6.
C TI
GE
Data Inspection
PE
Reporting
ME
IN S
NT
SE
D
A
K-B
RIS