KP4: Ageing and Life Extension – Process Integrity Onshore Template
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:
Rev. 2 10 June 2011
Page 1 of 12
KP4: Ageing and Life Extension – Process Integrity Onshore Template
Section A: Ageing and Life Extension (ALE) - Policy
(Questions for senior management – typically Operations Manager, Asset
Integrity Manager, Process Engineering Technical Authority)
Principal Questions:
1) What do you consider the ageing and life extension issues to be for
process safety?
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 topsides plant and equipment is suitable for
current and projected production profiles, and fluid composition;
b) modifications to the process system are integrated with the existing
production operations;
c) performance standards for safety critical elements on existing (as
well as new) process systems 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) obsolescence of software and hardware systems for control and
instrumentation for existing systems are identified, and alternatives
sourced;
g) redundant equipment that represents significant congestion and
aggravated explosion damage, or barrier to emergency response are
removed where this is reasonably practicable;
h) 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

Awareness of vibration issues leading to fatigue especially small
bore tubing
Rev. 2 10 June 2011
Page 2 of 12
KP4: Ageing and Life Extension – Process Integrity Onshore Template

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

Policy on ageing and life extension covering the projected lifetime
of the asset

Periodic review of design basis triggered by trends in production
profile, or time elapsed from previous review

Updated heat and material balances

Updated material selection guide

Key documentation P&IDs, Cause and Effect Diagrams, Hazardous
Area Classification Drawings, Operating Procedures etc. are
revised to reflect 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 wall thickness, and
absence of defects

A flexible hose register is 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 total PSVs successfully tested
in a period), and lagging (e.g. number of faults discovered during
testing of PSVs) indicators provided
Rev. 2 10 June 2011
Page 3 of 12
KP4: Ageing and Life Extension – Process Integrity Onshore Template
Section A: Ageing and Life Extension (ALE) - Policy
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
Rev. 2 10 June 2011
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 – Process Integrity Onshore Template
Section B: ALE - Organising
(Questions for senior management – typically Operations Manager, Asset
Integrity Manager, Process Engineering Technical Authority)
Principal Questions:
1) Who is responsible for:
2)
3)
4)
5)
6)
7)
a) Loss of Containment prevention;
b) Operational Risk Assessment;
c) Management of Change;
d) Maintenance and Testing of safety critical Plant Protection Systems?
How do these persons fit into the organization?
How is safety culture on ALE encouraged?
How are views on ALE 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 ageing issues

An understanding of life extension issues

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
Rev. 2 10 June 2011
Page 5 of 12
KP4: Ageing and Life Extension – Process Integrity Onshore Template
Section B: ALE - Organising
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
Rev. 2 10 June 2011
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 – Process Integrity Onshore Template
Section C: ALE - Planning and Implementing
(Questions for senior management – typically Process Engineering Technical
Authority, Asset Integrity Managers, EH & S Managers, Project Managers, OIMs)
Principal Questions:
1)
2)
3)
4)
5)
6)
7)
8)
What is your system for identifying hazards?
How do you assess the 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 does age trigger the above processes
Benchmarks sought in replies:

Formal safety assessment - Hazard and Operability Study/Hazard
Analysis, Failure Modes and Effects Criticality Analysis

Asset register of safety critical elements, Inherently Safer Design,
Risk Graph, Layers of Protection Analysis, Fault Tree Analysis

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, most vulnerable personnel exposure, frequency vs.
consequence

Integrated system

Work packs, work orders, operating instructions, written schemes of
examination, maintenance routines, performance standards

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

Key Performance Indicators are identified
Rev. 2 10 June 2011
Page 7 of 12
KP4: Ageing and Life Extension – Process Integrity Onshore Template
Section C: ALE - Planning and Implementing
Onshore Management:
Loss of containment
Operational Risk Assessment
Process modifications/additions
Offshore Operations:
N/A
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
Rev. 2 10 June 2011
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 – Process Integrity Onshore Template
Section D: ALE - Measuring Performance
(Questions for senior management – typically Process Engineering Technical
Authority, Maintenance Managers, Production Supervisors)
Principal Questions:
1) What codes, standards, recommended practices, guidelines, etc. have
2)
3)
4)
5)
6)
been identified as relevant to ageing & life-extension (ALE) and asset
integrity management (AIM)?
What parameters are measured during operation/inspection?
Where are the performance standards recorded?
How do you track progress for testing/inspection?
What are your key leading and lagging performance indicators?
How are these communicated to senior management?
Benchmarks sought in replies:

Benchmarking of design against current standards

Inspection methods and techniques are used to detect 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 process
plant and equipment
Rev. 2 10 June 2011
Page 9 of 12
KP4: Ageing and Life Extension – Process Integrity Onshore Template
Section D: ALE - Measuring Performance
Onshore Management:
Loss of containment
Operational Risk Assessment
Process modifications/additions
Offshore Operations:
N/A
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
Rev. 2 10 June 2011
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 – Process Integrity Onshore Template
Section E: ALE - Auditing and Reviewing Performance
(Questions for senior management – typically Asset Integrity Manager,
Maintenance Manager, Operations Manager, OIM, Process Engineering
Technical Authority)
Principal Questions:
1) How does the verification scheme address the ALE of process plant &
equipment (static & rotating) safety critical elements (SCEs)?
2) Who conducts a review of key performance indicators?
3) How frequently?
4) What results from such a review?
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
Rev. 2 10 June 2011
Page 11 of 12
KP4: Ageing and Life Extension – Process Integrity Onshore Template
Section E: ALE - Auditing and Reviewing Performance
Onshore Management:
Loss of containment
Operational Risk Assessment
Process modifications/additions
Offshore Operations:
N/A
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NONCOMPLIANCE
Court
proceedings
recommended
6
SIGNIFICANT
NONCOMPLIANCE
Enforcement
Notice Served
Rev. 2 10 June 2011
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