asset integrity management system (aims) evaluation checklist

Asset integrity management system (AIMS) evaluation checklist

Overview

Documentation is… Y / N Comments

Easy to read – format and layout clear

Quick to reference – check reference several aspects at random

Concise – clear and to the point

Minimal narrative – use of bullet points in checklists; use of tables and flowcharts in preference to wordy explanations

Considerations

AIMS evaluation and considerations Y/N Comments(N/A - not applicable)

1 Document control and preface

1.1 Document control register

1.2 Table of document name, document number, edition, version, date issued

1.3 Distribution list

1.4 Revision procedure

2 Contents

2.1 Plan structure – diagram format

2.2 Table of contents

2.3 List of figures, charts and tables

3 Introduction

3.1 Purpose

3.2 Scope

Asset integrity management system (AIMS) evaluation checklist – August 2012 of 16


3.2.1 Integration or relationship of plans: corrosion management inspection and repair planned maintenance inspection risk-based inspection reliability-centred maintenance

3.2.2 Integration with other company plans

3.3 Objectives

3.4 Location details

4 General

4.1 The AIMS addresses the following main elements as a minimum: corrosion management inspection and repair (e.g. vessels,

pipelines, instrumentation) safety critical elements (e.g. emergency shut down and

isolation equipment, fire protection and detection for plantand equipment)

instrumented protective functions planned maintenance inspection and repair, and fitness-for- purpose (e.g.

mobile plant) well head and subsurface well integrity

4.2 The AIMS delegates duties, responsibilities, authorities and accountabilities with respect to its development and implementation.

4.3 The AIMS demonstrates that any future development or activities can be addressed

4.4 All relevant personnel have access to relevant AIMS documentation and records



4.5 The AIMS incorporates or links to a quality management system as a mechanism for assisting in meeting the AIMS performance standards or key performance indicators (KPIs). KPIs should be readily available from the AIMS, such as: percentage of programme completed months of backlog backlog of critical items percentage emergency work weekly schedule complianceKPIs are regularly reviewed by supervisors and managers. Reports of outstanding critical maintenance and other exception reports are approved by the manager responsible for facility integrity

5 Facility or operation description

5.1 General

5.1.1 The facility or operation is sufficiently described to allow a clear understanding of the purpose of the asset and its activities and the controls in place to ensure that risks are managed to as low as reasonably practicable

5.1.2 The description includes as a minimum, where applicable: the physical controls in place to ensure that identified risks are

managed to as low as reasonably practicable key parties and responsibilities the geographical location and a site location plan key crossings environment description (e.g. oil, gas, sweet, sour) flora and fauna site meteorological conditions geotechnical considerations interaction with existing facilities



5.1.3 There is an overview of key plant and utilities, including: 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: is clear, specific and useable by the workforce defines objectives, strategies, plan, performance standards,

performance indicators and continuous improvement strategy clearly identifies systems, assets and equipment to be monitored by

specific programmes, including on-line inspection clearly defines the process of validation and verification against

regulatory requirements

6.1.2 Mechanisms are in place to ensure the accountability of senior management for the achievement of asset integrity management, such as: facility integrity is part of operator’s overall business management

system top management regularly reviews the technical health of the facility

and effectiveness of its monitoring every level of workforce has access to relevant integrity information

and regular briefings by management



6.1.3 Integrity assessment procedures and guidelines are in place, such as pipeline integrity management system

structural integrity management system technical change management system maintenance management manual inspection and corrosion engineering manual small bore piping integrity manual safety critical function maintenance and testing management system asset information system (documented asset register) well head and subsurface well integrity management

6.1.4 There is a documented maintenance strategy or plan that is derived from the policy for maintenance of systems and equipment, and is clear and actionable and includes: risk-based decision making to set appropriate maintenance options

(i.e. preventive, predictive and run to failure) reliability-centred maintenance concept applied (i.e. focus on systems

and equipment with safety consequences and frequent failure) describes the resources provided to achieve the plan, and how they

are provided describes how maintenance performance is monitored and measured describes how technical support is provided, and from whom defines safety critical elements specifies the process for identifying safety critical elements and their

corresponding performance standards in preventing or mitigating the initiation of a major accident event

Note: Safety critical elements are any part of the facility, plant or computer programmes whose failure will either cause or contribute to a major accident, or the purpose of which is to prevent or limit the effect of a major accident

6.1.5 Periodic review of the AIMS are scheduled to ensure its relevance and that objectives are met



6.2 Organisation and responsibility

6.2.1 All personnel involved in the AIMS are informed of their roles, responsibilities and accountabilities such that: the custodian of facility integrity is clearly identified, with job

description and authority the roles, responsibilities and communication between the operations,

maintenance and technical integrity group are clear the roles and responsibilities of other personnel such as support staff,

contractors and specialists are unambiguous

6.2.2 Key personnel have signed off on their understanding of their AIMS roles, responsibilities and accountabilities

6.2.3 Responsibilities and accountabilities under the AIMS are reviewed regularly and when with organisational changes are made

6.2.4 The AIMS responsibilities and accountabilities of all personnel align with their skills and training: key personnel involved in safeguarding the facility integrity are

identified there is a procedure for identifying the training needs of these

personnel, and a training or skills matrix there are competency requirements for personnel responsible for

specific areas of integrity safeguarding such as corrosion or erosion, pressure system, pipework and safety critical elements

specific skills that are outsourced are identified, and the work output and performance monitoring approach described

external accreditation required for specific skills of personnel (own and contractors) is defined

there is a competency assessment procedure personnel are trained in root cause analysis, HAZID, HAZOP and risk

management training records are maintained and audited

6.2.5 Interface between key personnel is clearly defined



6.3 Employee involvement and communication

6.3.1 “Front line” maintenance technicians are consulted when assessing risk, problem solving and devising maintenance work schedules and procedures: they are involved in task risk assessments (e.g. job safety analyses or

JSAs) and the provision of feedback to improve procedures they are involved in devising work schedules as required

6.3.2 Maintenance issues are discussed between the site-basedtechnicians or supervisors and office-based support staffThere is a daily communication protocol between site frontline staff and office-based support staff There is a mechanism for problems encountered on site by the technicians to be discussed and resolved with office based support staffContact can be made: daily for immediate issues monthly for planning purposes quarterly and annually for medium- and long-term planning

7 Planning: responsibility, hazard identification and risk management

7.1 General

7.1.1 Plans and procedures are in place to achieve the strategic objectives of safeguarding the facility integrity, such as: clear identification of critical activities and threats to integrity integrity management manual plan and procedures for inspection, audits and change management methodologies defined (i.e. risk-based inspections, reliability-centred

maintenance, instrumented protective function) clear process for defining safety critical elements and their

performance standards, plans and procedures for each type of asset, equipment or system (e.g. pipe work, pressure system, corrosion and erosion, structures)



7.1.2 Assumptions made within the AIMS are justified and backed by relevant information

7.1.3 Risk assessments are based on, and reference, appropriate standards (e.g. risk-based inspection - API 581)Note: See Part 3 of this guideline for simplified guidance on fitness-for-purpose and risk-based inspection

7.2 Objectives, plans and performance standards

7.2.1 The AIMS objectives, plans and standards are defined and verifiable, such as: pipeline integrity management system structural integrity management system technical change management system maintenance management manual inspection and corrosion engineering manual small bore piping integrity manual safety critical function maintenance and testing management system asset information system well head and subsurface well integrity management

7.2.2 The AIMS objectives, plans and standards reflect the responsibilities, legislative requirements and AIMS commitments

7.2.3 Plans are updated to reflect changes in performance standards, or outcomes of appraisals of the AIMS effectiveness

8 Safe operating procedures

8.1 Deferral of safety critical elements



8.1.1 There are procedures or documentation describing how deferrals are authorised and justified, and ensuring: any deferrals of safety critical items follow the change management

system of the SMS when a deferral is approved, it is stipulated whether that work item is

still referenced as a backlogNote: All work requests that have not been completed are “backlog” by definition

8.1.2 If maintenance of a safety critical element is deferred, the steps taken to identify and implement additional measures to restore the integrity of the barriers weakened by the deferral are described

8.1.3 Procedures and guidelines are in place for temporary measures or repairs, and are subject to an engineering assessment and given a “definedlife” prior to implementation When temporary measures are put in place, they must be limited to a specified time period and authorised in accordance with change management procedures, including a risk assessment.Note: Any change in the design of safety critical systems or equipment must be subject to change management system procedures and authorisation levelsA work order is generated on the maintenance scheduling software to record the defined life and to schedule when the temporary repair should be inspected, maintained and replaced with a conventional repair within the defined life

8.2 Maintenance and repair

8.2.1 A program has been developed and implemented on site for the routine inspection and maintenance of plant and equipment

8.2.2 Inspection and maintenance schedules are in place and are in line with manufacturers’ and legislative requirements, work practices and recommendations



8.2.3 Planned maintenance activities are conducted in line with procedures contained within the AIMS and: there is a mechanism to prioritise maintenance tasks, and any

differences between the priorities for corrective maintenance and those for planned maintenance are identified

work orders are screened for matters such as scope, planning and parts availability

risk assessment methodology is applied consistently to determine the time frame within which safety critical work is to be completed

safety critical work that is not completed by the nominated “required by date” is the subject of an exception report requiring management approval

priority is given to corrective maintenance that is necessary to avoid serious safety consequences

8.2.4 A process is in place to ensure that safety critical elements are identified and maintenance scheduled accordingly, and scheduled maintenance is prioritised with consideration for the safety and integrity impact of equipment, such as: critical function tests based on a checklist with acceptance parameters safety critical element acceptance criteria laid out in written schemes

of examination (WSE) performance measures in integrity manuals for security critical

elements or critical function testing performance standards defining the minimum acceptable standards

for a safety critical element in terms of functionality, reliability or availability, and survivability

failed functions not immediately repaired being the subject of a management-of-change report for sign off by the operation’s person in charge, with contingency measures in place for safe operation inclusive of an appropriate risk assessment

separate reports for the backlog of safety critical elements and equipment that is not safety critical



8.2.5 Procedures are in place for the periodic review of maintenance procedures to ensure: maintenance is being undertaken and equipment is safe and fit for

purpose before being returned to service potential improvements to the maintenance process are identified work is undertaken in accordance with documented procedures safety critical procedures include a checklist to be filed on completion the AIMS maintenance system includes performance monitoring

arrangements with agreed performance standards and performance indicators

office support staff analyse, monitor and verify the maintenance performance against appropriate key performance indicators, and these prompt queries and discussion between site- and office-based staff for compliance and continuous improvement

8.2.6 The AIMS plant and equipment register is used to record plant and equipment inspections, maintenance, repairs or modifications

8.2.7 Operations vehicles and plant are inspected by operations-authorised drivers or operators, and the results are recorded in a logbook

8.2.8 Plant or equipment found to be defective or dangerous is taken out of service and tagged as “out of service” until such time as a qualified technician has made suitable repairs or the equipment is replaced

8.2.9 Appropriate procedures and training are in place to ensure all maintenance activities and tasks are conducted in line with the AIMS

8.2.10 There is a documented procedure to ensure that defective or dangerous plant and equipment is reportedIf equipment is allowed to continue operating when it is known to be defective (e.g. a passing valve), there are procedures in place to identify what other barriers and defences need to be implemented to compensate.Note: A risk assessment is required to arrive at mitigating measures for continued operation

8.3 Employee selection competency and training



8.3.1 A competency and skills matrix defines the competency criteria and safety attributes of each position

8.3.2 Evidence of statutory competencies is required for relevant positions and copies of certificates are retained on site

8.3.3 There is a process to capture the review of position specifications

8.3.4 All personnel are aware of their roles and responsibilities upon commencement of employment

8.3.5 Employee competence is assessed as part of a periodic performance review

8.3.6 Training programs are adequately funded and reviewed, and reassessed periodically to ensure effectiveness

8.4 Workplace environment

8.4.1 The project management team has developed the AIMS to ensure and promote a safe working environment

9 Inspection, testing, monitoring and reporting

9.1 General



9.1.1 There are processes covering the inspection, testing and monitoring of site activities, plant and equipment for the operation, including: procedures for ensuring plant is checked before use planned regime of workplace AIMS inspections work activity observations pre-operation inspections of vehicles and plant inspections and testing of electrical equipment inspections and testing of cranes and lifting equipment inspections and testing of pressure vessels and pressure testing

equipment inspections and testing of emergency, first aid, fire and spill control

equipment inspections and testing of well integrity

9.1.2 Inspections follow an agreed format and are documented

9.1.3 A corrective action register prioritises, tracks and closes-out actions and improvements

10 Audit, verification, review and improvement

10.1

Asset integrity audit

10.1.1 The audit and review approach of the AIMS is demonstrated through: key performance indicators used in daily and monthly operations

reports monthly facility integrity reports monthly facility technical change reports validation and verification schemes regular internal and external audits and reviews

10.1.2 The system and program of AIMS audits includes both internal and independent audits



10.1.3 The AIMS audits enable verification that the AIMS arrangements meet specified performance standards and allow opportunities for system improvement to be identified

10.1.4 The methodology for conducting AIMS audits is described, including: scope and objectives criteria for selection of audit teams and leaders reporting requirements

10.1.5 The AIMS audits are conducted by suitably competent personnel and the AIMS personnel are involved, and: there is a policy and procedure for facility integrity audit the planning for audits is described, including whether they are based

on the status and importance of the activity the selection of personnel to conduct each audit is described independent competent persons are used for audits and verification

10.1.6 Corrective actions are prioritised, assigned responsibility, and allocated expected completion dates

10.1.7 The AIMS audit findings are submitted in a formal report along with any corrective action requests to appropriate project personnel

10.1.8 Follow-up actions on audit findings are monitored for suitable resolution and timely close-out

10.1.9 The AIMS audit reports are disseminated to involved stakeholders and authorities

10.2

Review and improvement

10.2.1 A process is in place to capture corrective actions and follow-up requirements resulting from the audit or assessment, and ensure close-out in a timely manner

10.2.2 The AIMS performance is benchmarked against other organisational, operational and industry data

11 Document and record control procedures



11.1

In general, the AIMS describes whether records are centrally kept and: integrity records are maintained to demonstrate achievement of the

performance standards of the systems and equipment records are maintained for non-compliances, deviations, deferrals, corrective

actions and remedial measures taken the validation and verification results of specialist contractors are recorded records accessible to relevant (i.e. site and office) personnel the form in which the records are kept and what the retention time is

11.1.1 There is a document identification system that allows each document to be uniquely identified

11.1.2 All documents developed utilise the document identification system

11.1.3 All documents are developed in line with an agreed format

11.1.4 All documents intended solely for the operation and developed by external parties are reproduced (with consent of the external party) in line with the agreed format and identification system

11.1.5 Where a document hierarchy exists, this is detailed within the document control procedures

11.1.6 Document development is undertaken by personnel who are suitably qualified and competent

11.1.7 All documents are subject to a defined review process that includes the participation of relevant personnel

11.1.8 The review of documents is recorded either on the document master drafts or by some other means (e.g. document review register)

11.1.9 All documents are subject to a defined authorisation process that includes those peoples whose responsibility it falls under, as per the organisation structure

11.1.10

The authorisation of documents is recorded either on the document final draft or by some other means (e.g. document authorisation register)



11.1.11

Where applicable, documents include references to material gathered from other documentation, either internal or external to the operation’s organisation

11.1.12

An effective document change management process is in place to ensure that: changes to the operation (any internal or external factors or

references) are captured in the corresponding documents dissemination of altered documentation is timely and effective relevant personnel are made aware of changes to documentation superseded or redundant documents are replaced at all locations on

site and within the organisation

11.1.13

The document control process captures all correspondence that will, or has the potential to influence the AIMS aspects of the operation

11.1.14

Documents are marked as either controlled or uncontrolled as is applicable, and this process is managed effectively

11.1.15

Documentation is archived in accordance with statutory requirements
