KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
INSTALLATION or
DUTYHOLDER
Key Persons
interviewed
DATES(S)
Company
Summary of Inspection Traffic Lights
IMT and INSPECTOR(S)
Position
Red
6 5
Amber Green W
4 3 2 1 0
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:
August 2011 V1.0
Page 1 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section A: Ageing & Life Extension – Policy and Leadership
(Questions for senior management – typically Operations Manager, Asset
Integrity Manager, Safety Engineering Technical Authority)
Principal Questions:
1) What do you consider the ageing and life extension issues to be for
Fire, Explosion and Hazardous Fume (FEHF:DMP) detection, mitigation
and protective systems?
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 the policies that senior management has in place to ensure
that:
a) the design basis for FEHF:DMP equipment is suitable for current
and projected Major Accident Hazards (MAH);
b) modifications to the FEHF:DMP systems are competed with a full
consideration of the current MAH risk profile of an installation;
c) performance standards for safety critical elements on existing (as
well as new) FEHF:DMP equipment 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) redundant equipment that represents significant congestion and
aggravated explosion damage, or barrier to emergency response
are removed where this is reasonably practicable;
g) 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 operations.
5) What are the Key Performance Indicators used to indicate the asset
integrity status to Senior Managers?
Benchmarks 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

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
August 2011 V1.0
Page 2 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section A: Ageing & Life Extension – Policy and Leadership
 Policy on ageing and life extension covering the projected lifetime
of the asset

Periodic review of design basis triggered by trends in MAH profile,
or time elapsed from previous review

Updated consequence, vulnerability and probability models

Key documentation QRA, P&IDs, Cause and Effect Diagrams,
Hazardous Area Classification Drawings, Operating Procedures
etc. are revised to reflect any 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 PFP condition,
thickness, and absence of defects

Registers 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 successful TR integrity,
detectors and Active fire protection systems tested in a period),
and lagging (e.g. number of faults discovered during testing of Fire
pumps, detectors, PFP, fire walls and penetrations HVAC
systems) indicators provided

Ageing and life extension (ALE) policy owned by senior
management
Senior management has responsibility for implementing ALE
policy
Senior management support for equipment/system replacement
Asset Integrity Management (AIM) addresses ALE
Fitness for purpose demonstrations are described
References to codes, standards & guidance, for example:
o OSD Info sheets 1/2006, 2/2006, 3/2006 4/2009 BS 13702, IP
15 SPC 30
o HSE Research Report RR 509 Plant Ageing (Management of
equipment containing hazardous fluids or pressure)
o Relevant Energy Institute publications
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August 2011 V1.0
Page 3 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section A: Ageing & Life – Extension Policy and Leadership
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
August 2011 V1.0
5
GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4
PARTIAL
COMPLIANCE
GENERAL
COMPLIANCE
GENERAL
COMPLIANCE
Letter
Verbal advice
No findings
3
2
1
NOT
INSPECTED
0
Page 4 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section B: Ageing & Life – Organisation
(Questions for senior management – typically Operations Manager, Asset
Integrity Manager, Safety Engineering Technical Authority)
Principal Questions:
1) Who is responsible for:
a) Major Accident Hazard identification and risk assessment;
b) The fire & explosion ALE policy;
c) Conducting fire & explosion integrity condition assessments and
life-extension studies etc. for the fire & explosion integrity system
2)
3)
4)
5)
6)
d) Maintenance and Testing of safety critical: detection, control
/mitigation and protective systems;
e) Operational Risk Assessment;
f) Management of Change;
How do these persons fit into the organization?
How are views on risk management, including downgraded situations
involving SCE’s communicated to and from the workforce?
How do you document Operational Controls and Maintenance Records
How do you assure the competency of personnel involved in the
management, operation, inspection, and maintenance of plant and
equipment?
How is competence assured for contractors?
Benchmarks sought in replies:

An understanding of thee need for monitoring & trending data

An understanding of life extension issues for fire & blast resistance

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
August 2011 V1.0
Page 5 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section B: Ageing & Life – Organisation
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
August 2011 V1.0
Page 6 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section C: Ageing & Life Extension – Planning and Implementation
(Questions for senior management – typically Safety Engineering Technical
Authority, Asset Integrity Managers, EH & S Managers, Project Managers,
OIMs)
Principal Questions:
What is your system for hazard identification?
How do you assess risk?
How do you establish the protective and mitigation measures?
How do you prioritise the work?
Is maintenance, inspection, or testing contracted out?
How is implementation controlled?
How is change controlled?
How are downgraded SCE’s for fire, explosion and hazardous fume
managed
9) How is performance of the SCE’s monitored and trended such that age
and condition trigger the above processes
1)
2)
3)
4)
5)
6)
7)
8)
Benchmarks sought in replies:

Risk Based Inspection, Campaign, Breakdown, Condition
Monitoring

Periodic replacement, testing and inspection

Operating and Maintenance records, including service life

Incident data, internal/external

Risk targets

Integrated system

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

Explanation of how equipment subject to ageing is selected and
identified
Review of the suitability of the performance standards
Evaluation of wear, deterioration and damage in service
Review for operation outside of design limits, and for changed
design standards
Obsolescence identified and managed
Plans for replacement and provision of spares
Targeted inspection and maintenance, including difficult to access
equipment
Life extension studies and fitness for purpose demonstrations
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August 2011 V1.0
Page 7 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section C: Ageing & Life Extension – Planning and Implementation
available
 Condition of mitigation systems such as PFP, gas detection or
deluge in place established
 The original design criteria and any information that demonstrates
that the original design criteria are no longer valid available




Platform modifications, additions, any repairs / strengthening
particularly of the TR documented;
Changes of use violating the original design or previous integrity
assessment assessed;
Departures from the original basis of design e.g. increased gas
inventory or higher throughput in separators assessed and
actioned;
The versions of the codes used dispersion or explosion models
suitable and validated regularly

Firewater pump or main ring main failure resulting in overall
deluge failure evaluated and action planned

corrosion/blast wall integrity compromise detector obsolescence
considered and monitored/ action planned .
August 2011 V1.0
Page 8 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section C: Ageing & Life Extension – Planning and Implementation
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
August 2011 V1.0
5
GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4
PARTIAL
COMPLIANCE
GENERAL
COMPLIANCE
GENERAL
COMPLIANCE
Letter
Verbal advice
No findings
3
2
1
NOT
INSPECTED
0
Page 9 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section D: Ageing & Life Extension – Measuring Performance
(Questions for senior management – typically Safety Engineering Technical
Authority, Maintenance Managers, Production Supervisors)
Principal Questions:
1. What codes, standards, recommended practices, guidelines, etc.
have been identified as relevant to ageing & life-extension (ALE)
and asset integrity management (AIM) for fire explosion and
hazardous fume MAH’s?
2. What specific key performance indicators (KPIs), 'traffic lights' or
similar are used to review the fire & explosion condition with
respect to ageing and the effectiveness of the maintenance, testing
and inspection system?
3. What inspection methods are used to detect ageing or deteriorating
performance of the FEDMS? How does the inspection philosophy
allow for the detection of ageing, e.g.
4. Planning and frequency of inspections and maintenance in
recognition of ageing mechanisms, including integration of
baseline, periodic and special inspections
5. Use of maintenance procedures which consider the need for a more
detailed inspection if a period of life extension is to be justified or
deterioration from ageing mechanisms is detected
6. Consideration of scheduling of IMR interventions in light of
deterioration rates, availability of competent services, reliability of
techniques and confidence for near- and long-term assurance of
integrity
7. What risk-based methods are employed that allow for loss of
integrity from ageing of detection and mitigation systems (with key
supporting references).
8. What leading or lagging indicators are used to indicate components
/ structure or equipment that may not be performing as required or
showing signs of deterioration in their integrity or performance?
9. What reference is made to codes, standards, recommended
practices, guidelines, etc., relevant to ageing & life-extension (ALE)
and fire & explosion integrity management?
10. How does the duty holder evaluate the implications of revised or
new codes, standards, guidelines, etc., and adapt fire & explosion
inspection and maintenance, etc., where necessary?
11. What parameters are measured during operation/inspection/ fault
condition?
12. Where are the performance standards recorded?
13. How do you track progress for testing/inspection?
14. How are these communicated to senior management?
August 2011 V1.0
Page 10 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section D: Ageing & Life Extension – Measuring Performance
Benchmarks sought in replies:







Leading and lagging KPIs to monitor impact of ALE are defined
Management reviews KPIs and acts
Contractor and 3rd party maintenance findings reviewed
Procedures in place to detect ageing
Ageing processes monitored
Failure trends identified
Benchmarking of design against current standards

Inspection methods and techniques are used to detect and trend
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

Senior Management is aware of the status and condition of plant
and equipment related to Fire, Explosion and Toxic Fume
management
August 2011 V1.0
Page 11 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section D: Ageing & Life Extension – Measuring Performance
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
August 2011 V1.0
5
GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4
PARTIAL
COMPLIANCE
GENERAL
COMPLIANCE
GENERAL
COMPLIANCE
Letter
Verbal advice
No findings
3
2
1
NOT
INSPECTED
0
Page 12 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section E: Ageing & Life Extension – Auditing and Reviewing Performance
(Questions for senior management – typically Asset Integrity Manager,
Maintenance Manager, Operations Manager, OIM, safety Engineering Technical
Authority)
Principal Questions:
1) How does the verification scheme address the ALE of Fire, Explosion
2)
3)
4)
5)
and hazardous fume detection control, mitigation and protective
system safety critical elements (SCEs)?
Who conducts a review of the key performance indicators?
How frequently?
What results from such a review?
How are recommendations to senior management made with respect
to the level of resources required to maintain fire & explosion integrity?
6) How are lessons learned and trended for incident, accident and near-
miss data and how is this being used to improve and the AIM system?
7) Are performance standards on the loss of integrity from deterioration
associated with ageing and life extension available for all fire &
explosion detection and mitigation systems safety critical elements
(SCEs)?
8) To what extent has the verification process identified any deterioration
from ageing mechanisms and associated loss of integrity or
demonstrated that integrity has not been compromised by ageing
mechanisms?
9) What evidence is there that fire & explosion SCEs meet / do not meet
performance standards? What anomalies have been identified?
10) What improvements have been identified and implemented as a result
of the verification process? How is their implementation monitored?
11) How has the senior management satisfied itself that the verification
process has adequately addressed any loss of integrity associated
with ALE?
12) What conclusions can be drawn directly from the verification process
on the risks from ALE to the overall fire & explosion integrity of the
installation?
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

Formal audit programme which addresses ALE management
processes
August 2011 V1.0
Page 13 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section E: Ageing & Life Extension – Auditing and Reviewing Performance
 Audit findings reviewed by senior management
 Management improvements identified
 SCE verification process addresses ALE issues
August 2011 V1.0
Page 14 of 15
KP4: Ageing and Life Extension – Inspection Template – Fire and Explosion
Section E: Ageing & Life Extension Auditing and Reviewing Performance
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
August 2011 V1.0
5
GENERAL
NONCOMPLIANCE
Letter &
changes made
to intervention
4
PARTIAL
COMPLIANCE
GENERAL
COMPLIANCE
GENERAL
COMPLIANCE
Letter
Verbal advice
No findings
3
2
1
NOT
INSPECTED
0
Page 15 of 15