Plant Asset Management

Integrity Management Review Process

Overview
A structured review of a clients Integrity Management System with a view to
benchmarking against current industry best practice (as required), identifying
perceived deficiencies and establishing improvement plans.
The process is carried out by a combination of questionnaire, staff interviews and a
review of existing documentation (policies, procedures, and integrity history [e.g.
monitoring and inspection data)
Objectives

To confirm the key drivers for improvements in integrity management, e.g.

o Business requirements
o Health, Safety and Environmental commitments
To identify and highlight areas of best-practice
To identify potential shortfalls in existing integrity management systems, e.g.
o Policies, procedures and guidelines
o Organisational issues
o Record keeping, activity scheduling, etc
To provide recommendations for improvements to the integrity management
strategy
To identify key performance indicators which could be used to measure the
effectiveness of the integrity management strategy
To review the applicability of supporting methodologies (e.g. RBI) to increase
the effectiveness of integrity management

Scope
The review process covers the following elements (or equivalents), which typically
form part of the Integrity Management System:

Policy & Strategic Objectives

Organisation & Resources
Risk Management
Design & Construction
Operations Practice
Maintenance
Inspection & Monitoring
Management of Change
Information Management
Staff Competency
Third Party Services
Anomalies, Repairs & Failure Analysis

System Review & Audit

Policy & Strategic Objectives

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Does the client have an Integrity

Management Policy?
Is the Policy endorsed by the clients
Senior Management?
How is the Integrity Management Policy
communicated to staff?
Is the Integrity Management Policy
supported by appropriate reference
material (procedures, guidelines, etc.)?
What are the main drivers for integrity
management?
How are staff involved in the
development of Integrity Management
Policy and supporting activities?
Does the integrity management approach
define any key performance targets?
Is planning related to integrity
management fully integrated with;
Safety Cases?
Maintenance strategy?
Performance standards?
Operations?
Are there mechanisms to share integrity
knowledge within the organisation e.g.
lessons learned reporting?
Are measures in place to record the cost
of Integrity Management e.g. the costs of
corrosion directs/indirects?
Are records of loss of containment (e.g.
for hydrocarbons) maintained?
What performance measures are in place
to monitor the success of integrity
management activities? Are any KPIs
relating to integrity management used at
present?
Is integrity management a key feature of
site safety tours and regular site tours by
Senior Management?

Organisation & Resources

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Is overall responsibility for integrity

management assigned to a particular
named individual or function?
Is there an organisation chart specifically
associated with integrity management? Is
this fully documented and updated as
required?
Are roles and responsibilities for
individuals involved in Integrity
Management clearly defined and
documented?
Are authorities and reporting routes
clearly defined?
How are interfaces between the various
departments (Engineering, Maintenance,
Operations, SH&E, Support, etc.)
managed?
How are Integrity Management activities
budgeted and resourced?
Are sufficient resources available to
support all aspects of the Integrity
Management strategy?
What procedures are in place to assess
the competence of staff involved in
delivering the Integrity Management
strategy?
Has corrosion awareness training been
provided to non-specialist staff involved
in integrity management?
How are staff continuity issues addressed
within the Integrity Management system?
What involvement do contractors/third
parties have in the existing Integrity
Management strategy? How is their
involvement managed?

Risk Management
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What high-level approaches are used to

determine equipment inspection, testing
and maintenance requirements (e.g. RBI,
RCM, SIL, etc.)
What are the main drivers for applying a
risk approach to maintenance and
integrity?
What approach(es) to risk analysis have
been adopted?
Who manages the process(es)?
What data was used to support the
process(es)?
How well are the plant operating
conditions and environment known?
How are deterioration mechanisms and
failure modes identified and likelihood of
failure determined?
What data relating to plant reliability
and failure history is available?
What information relating to the
consequences of failure is available?
What factors determine the
consequences of failure
How are risks (criticality) of equipment
ranked or categorised?
What methods or factors are used to
determine equipment inspection, testing
and maintenance intervals
Are special measures considered for
equipment with high consequences of
failure?
What measures are in place to address
the risks from deteriorating equipment
What procedures are used to prepare
static equipment (e.g. pressure vessels,
tanks) for inspection?
Has a risk assessment of process sampling
activities been carried out?
How are the risks associated with small
bore pipework failures addressed?
How are the risks associated with
vibration fatigue of pipework/equipment
addressed?
How are risks associated with leakage
from bolted flanged joints addressed?
What procedures are in place to review
the results of inspection, testing and
maintenance and re-assess integrity
management requirements?

Design & Construction

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How are materials and corrosion

considerations addressed in the design of
new facilities or modification of existing
plant?
How is Quality Assurance addressed
throughout design and construction?
How are codes and standards applied
during design?
What specifications are produced for new
or replacement equipment? How is design
fitness-for-service ensured?
Have steps been taken to reduce the
need for inspections as part of
equipment fabrication (e.g. through the
use of preferred fabricators)?
What safety and hazard assessment
studies are carried out at the design
stage (e.g. HAZOP, HAZID, PHA, SIL)?
How is design safety addressed?
How are plant modifications addressed in
the Asset Register?
How are plant modifications addressed in
the Integrity Management System (e.g.
baseline inspections and
inspection/monitoring requirements)?
Is on-site work carried out according to a
Construction Quality Plan? What is
covered by the plan?
How is on-site welding managed (e.g.
weld procedures, personnel, testing &
assurance)?
How are actions or changes arising from
construction work listed and tracked?
How is the requirement for
vessel/pipework cleaning or flushing
assessed?
What are the procedures for pressure
and/or leak testing?
What is the procedure for handover to
operations?

Operations Practice
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Are the relevant Technical Authorities

involved in the definition of the safe
operating envelope?
How are safe operating parameters and
limits collated and communicated to
operations staff?
Are the implications of operating outside
of the safe operating envelope clearly
understood?
How are key operational data recorded
and compared against safe limits?
How are excursions outside of the safe
operating envelope communicated to
Technical Authorities?
Does the facility have a full set of
operating procedures? Do these make
reference to safe operating limits?
Is there a procedure for the management
of shift handovers?
What approach is used to determine
isolation procedures?
What procedure is used for identification
and access to locked valves?
What procedures are used for equipment
mothballing or long-term isolations?
What arrangements are in place for
sampling and analysis of process fluids?
What procedures are applied to ensure
that air does not enter the venting and
flare system(s)?
What corrosion control systems are used
(e.g. corrosion inhibitors, cathodic
protection, coatings etc.)?
How is effectiveness of the corrosion
control systems monitored?

Maintenance
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What is the asset Maintenance Strategy?

Is a risk-based approach applied to the
maintenance of equipment?
How are Safety Critical Elements
addressed within the maintenance
programme?
Are any items of plant covered by
healthcare contracts?
Does the asset use a computerised
maintenance management system
(CMMS)?
How are overdue maintenance activities
identified and managed?
How are the results of maintenance or
testing activities analysed and reported?
How are recommendations followed up?
What procedures are applied to the
inspection and storage of spare parts?
How are spare parts stockholding
requirements determined?
What controls are applied to ensure that
delivered equipment, materials or spare
parts are fit-for-service?

Inspection & Monitoring

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What mechanisms are used to determine

requirements for inspection, monitoring
and mitigation activities?
Are all corrosion monitoring and
inspection locations/datum points clearly
identified within engineering drawing
(P&IDs, isometrics) and within applicable
workpacks?
What mechanisms are there for carrying
out and reporting opportunity
inspections, e.g. as part of unplanned
equipment downtime?
What procedures are used to inspect
normally inaccessible areas of plant?
What procedures are used to determine
inspection datums e.g. TMLs?
How are inspection anomalies managed?
Is there a defined procedure highlighting
the actions required for each level of
anomaly?
Does minimum design thickness data
exist for all vessels? If not, what
procedures are applied?
What are the minimum acceptable wall
thicknesses for piping systems? Have
these been calculated according to a
recognised standard e.g. ASME B31.3?
Details of inspection workpacks?
Is appropriate consideration given to the
limitations of inspection and monitoring
techniques during evaluation of the data?
What procedures are in place to define
the requirements for inspection
deferrals?
Does the asset produce an annual
Integrity Statement or Integrity Status
Report?
Are any areas of plant specifically
excluded from inspection or monitoring
programmes?
Are corrosion control matrices employed
to monitor and control the main
corrosion threats?
Are corrosion inhibitor dosing levels
correlated with fluid volumes to optimise
dosing?
How are corrosion rate excursions
investigated (and correlated with
production/chemical data)?
How are remedial actions achieved? For
example what procedures are used to
optimise inhibitor treatments?
What procedures are in place to ensure
that corrosion probes (e.g. ER or LPR)
are functioning?
How often are corrosion coupons

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retrieved for weight loss assessment and

examination?
What procedures and frequencies are
used for the management of corrosion
probe data?
What procedures are used to evaluate
the root cause of corrosion incidents and
process upsets leading to increased
monitored corrosion rates?
What procedures are in place to examine
insulation systems and prioritise
refurbishment and inspection
programmes?
Have non-invasive techniques for CUI
been successful in detecting areas of
damage or wet insulation?
Are paint specifications applied for
repainting programmes do these reflect
current best-practice?
Are paint inspectors employed to oversee
repainting works?
Are written procedures in place for all
inspection and monitoring activities?

Management of Change
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Is there a specific policy or procedure

that addresses management of change?
Who has overall responsibility for the
management of change process?
What activities or situations are covered
by the management of change process?
Does the management of change process
ensure that all applicable documentation
and procedures are updated as required?
How are recommendations arising from
the management of change process
followed up?
Does a changer register exist?
How are materials/corrosion issues
addressed as part of major
projects/equipment modifications?
Are procedures in place to feedback
operational experience into to
equipment design and modifications?
What determines the inspection
requirements of newly installed plant?
Are there procedures in place for
evaluating the impact on integrity of
changes to product composition or
process chemistry?

Information Management
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Is the Integrity Management System

supported by a formal Asset Register?
How is the Asset Register updated and
maintained?
Are any software tools used in the
development of Integrity Management
plans (e.g. RBI)?
How is corrosion monitoring, process
monitoring and inspection data stored
and retrieved?
What procedures are used to manage and
rectify inspection anomalies?
What arrangements are in place to
interpret integrity data?
How is inspection and monitoring data
used in the integrity review process?
What procedures are applied to ensure
that plant documentation (e.g. P&IDs,
PFDs, Start-up & Emergency Shut-Down
procedures) is up to date?
How are changes to inspection and/or
monitoring requirements documented?
Is data associated with equipment
failures and evidence of deterioration
maintained on a Tag basis?

Staff Competency
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What procedures are in place to assess

the competence of staff involved in
delivering the Integrity Management
strategy?
Are training programmes provided for key
staff involved in the Integrity
Management System?
What induction is required for staff
specifically involved in delivery of the
Integrity Management System?
Which internal staff positions support
delivery of the Integrity Management
System?
How long have the internal staff
supporting the Integrity Management
System been in post?
Is there evidence of awareness of an
integrity management approach at all
levels within the organisation?
Has corrosion awareness training been
provided to non-specialist staff involved
in integrity management?
Does the organization have any difficulty
in recruiting staff for positions in the
integrity organisation?

Third Party Services

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What involvement do contractors/third

parties have in the existing Integrity
Management strategy?
How is their involvement managed? e.g.
there a management interface document
associated with the Integrity
Management System?
What measures are taken to ensure
continuity of service level (e.g. arising
from staff turnover)?
How are third parties engaged in reviews
and audits?
What measures are taken to ensure that
third party staff involved in Integrity
Management decision making have
adequate experience and/or
qualifications?
Who provides training for staff from third
party service providers?
What information relating to asset
integrity is held by third party service
providers?
What issues would arise from changing
third party service providers?
How familiar are third party service
providers with the clients facilities?

Anomalies, Repairs & Failure Analysis

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How are failure investigations managed?

Is there a defined procedure for
procuring services?
Who is involved in the failure analysis
procedure?
If integrity damage is spotted by
operational staff how is this followed
up?
Are there any examples where corrosion
mitigation measures have needed to be
changed as a result of failures/defects
and/or significant process changes?
What mechanisms are there to share
knowledge of failures and corrosion
incidents within the organisation?
How is the application of temporary
repairs managed?
How is the life of temporary repairs
determined?
What additional integrity management
requirements are placed on temporary
repairs?

System Review & Audit

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What are the requirements for a review

of the Integrity Management System?
Who is involved in the review process?
How often is the Integrity Management
System audited?
Who is involved in the auditing process?
How does management assess the
effectiveness of the Integrity
Management System, including
organisation, processes & procedures?
What aspects are covered in the review
process?
How are contractors and other relevant
third parties engaged in the review/audit
process?
How are the findings of the review/audit
recorded, and any actions followed up?
How are the findings analysed to
determine what constitutes best-practice
or deficiencies in the Integrity
Management System?
How are the key findings of the
review/audit communicated to staff?