KP4: Ageing and Life Extension - Inspection Template - Mechanical
INSTALLATION or
DUTYHOLDER
Key Persons
interviewed
DATES(S)
Company
Summary of Inspection Traffic Lights
IMT and INSPECTOR(S)
Position
Red
6 5
Amber Green
4 3 2
1
Section A: Ageing and Life Extension(Degradation &
Deterioration) (ALE) - Policy
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 12
W
0
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Section A: Ageing & Life Extension – Policy and Leadership
Principal Questions:
1. Describe the policies that senior management have put in place for
integrity management of safety critical elements and in particular
ageing and life extension issues.
2. To what extent are senior managers aware of the performance of the
systems designed to maintain the integrity of safety-critical assets,
and what is their commitment to ensuring that such assets remain fit
for service at all times?
Benchmarks sought in replies:

Explicit recognition of the significance of ageing issues;

Understanding of the challenges to ALE;

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 referenced;
Topic Questions: (TA - Mechanical Systems – Hydrocarbon containment):
The duty holder shall demonstrate sufficient knowledge with reference to selected
safety critical elements
A-1.
What does the DH consider the principal ALE issues that affect the integrity
of the hydrocarbon containment plant?
A-2.
What ageing mechanisms & life extension issues have been identified for
the hydrocarbon containment plant throughout the installation(s)?
A-3.
Have all the ALE issues that affect the hydrocarbon containment plant t
been identified – has a gap analysis been performed? Against which
benchmarks?
A-4.
How have the ALE issues that affect hydrocarbon containment been
incorporated into the AIM system?
A-5.
What risks have been identified as resulting from hydrocarbon containment
integrity-related ALE issues?
August 2011 V1.0
Page 2 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Topic Questions: (TA - Mechanical Systems – Cranes and machinery):
The duty holder shall demonstrate sufficient knowledge with reference to selected
safety critical elements
A-6.
What does the DH consider to be the principal ALE issues that affect the
integrity of the cranes and machinery?
A-7.
What ageing mechanisms & life extension issues have been identified for
the cranes and machinery on the installation(s)?
A-8.
Have all the ALE issues that affect the cranes and machinery – has a gap
analysis been performed? Against which benchmarks?
A-9.
How have the ALE issues that affect cranes and machinery been
incorporated into the AIM system?
A-10. What risks have been identified as resulting from cranes and machinery
integrity-related ALE issues?
August 2011 V1.0
Page 3 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
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 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Section B: Ageing & Life – Organisation
Principal Questions:
1. What management processes are in place to ensure delivery of the ALE
policy?
2. How does the leadership team know that the people involved are competent
to perform the duties that the leadership team expect them to perform?
Benchmarks sought in replies:
 Roles and responsibilities are defined
 Defined responsibility for condition assessments & life extension studies
 Management & development of personnel competency
 Management of contractor and 3rd party competency
 Retention of corporate knowledge
 Documentation management (asset registers / drawings)
 Management of change
Topic Questions (TA - Mechanical Systems – Hydrocarbon containment):
The duty holder shall demonstrate sufficient capability with reference to selected safety
critical elements
B-1.
Who is responsible for conducting condition assessments and life-extension
studies etc for the hydrocarbon containment system?
B-2.
Who is responsible for approving condition assessments and life-extension
studies and determining any limitations on future use?
B-3.
How are key issues, signs or symptoms being communicated to operations or
maintenance personnel so they are aware of what to be alert to as indicators of
ageing plant?
Topic Questions: (TA - Mechanical Systems – Cranes and machinery):
The duty holder shall demonstrate sufficient capability with reference to selected safety
critical elements
B-4.
Who is responsible for conducting condition assessments and life-extension
studies etc for cranes and machinery?
B-5.
Who is responsible for approving condition assessments and life-extension
studies and determining any limitations on future use?
B-6.
How are key issues, signs or symptoms being communicated to operations or
maintenance personnel so they are aware of what to be alert to as indicators of
ageing plant?
August 2011 V1.0
Page 5 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Section B: Ageing & Life – Organisation
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 6 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Section C: Ageing & Life Extension – Planning and Implementation
Principal Questions:
1. Describe the methods used to indentify ageing of safety critical elements.
2. Explain how the integrity management system ensures that the risks
associated with ageing issues and life extension are controlled effectively.
Benchmarks sought in replies:

Explanation of how equipment subject to ageing is selected and identified;

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;

Planned and targeted inspection and maintenance;

Life extension studies and fitness for purpose demonstrations;

Remedial actions.
Topic Questions (Mechanical systems integrity – hydrocarbon containment):
The duty holder shall demonstrate sufficient capability with reference to selected safety
critical elements
C-1.
What additional inspection & maintenance considerations (e.g. RBI studies etc)
are in place for hydrocarbon containment equipment in respect of:





Process vessels
PSVs
Process piping, flange bolting, supports, sbcs & tubing etc
Process valves
Drains & flare lines
Topic Questions (Mechanical systems integrity – cranes and machinery):
The duty holder shall demonstrate sufficient capability with reference to selected safety
critical elements
C-2.
What additional inspection & maintenance considerations (e.g. FMECA studies
etc) are in place for cranes and machinery in respect of:





Crane structure & slew bearing
Crane motors / gearboxes / brakes / winches / wire ropes etc
Crane prime mover, crane control system, hydraulic system
Safety devices, ASLI, GOP
Oil export pumps
August 2011 V1.0
Page 7 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
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 8 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Section D: Ageing & Life Extension – Measuring Performance
Principal Questions:
1. How are the risks arising from ageing and life extension being controlled
effectively?
2. Describe the performance indicators used to demonstrate the current
condition of the installation structure.
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
Topic Questions (Mechanical systems integrity – hydrocarbon containment):
The duty holder shall demonstrate sufficient capability with reference to selected safety
critical elements
D-1.



Describe how the hydrocarbon containment system is assessed for continued
suitability: (e.g. suitability of repairs, fitness for service justifications, life extension
studies etc)
Process vessels
Process piping, flange bolting, pipe supports
Process valves
Topic Questions (Mechanical systems integrity – cranes and machinery):
The duty holder shall demonstrate sufficient capability with reference to selected safety
critical elements
D-2.



Describe how the cranes and machinery are assessed for continued suitability:
Cranes
Oil export pumps
Gas compressors
August 2011 V1.0
Page 9 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
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 10 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Section E: Ageing & Life Extension – Auditing and Reviewing Performance
Principal Questions:
1. How does the duty holder review the effectiveness of their inspection,
maintenance and repair activities?
2. Describe the processes in place to audit the ageing and life extension
aspects of their integrity management system.
3. Describe how the verification system is used to address deterioration
associated with ageing and life extension issues.
Benchmarks sought in replies:
 Formal audit programme which addresses ALE management processes
 Management improvements identified
 SCE verification process addresses ALE issues
August 2011 V1.0
Page 11 of 12
KP4: Ageing and Life Extension - Inspection Template - Mechanical
Section E: Ageing & Life Extension – Auditing & 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 12 of 12