This presentation discusses the theory, application and case study on Asset Integrity Management and Process Safety.

1. Technical Paper Presentation:
Case Study: Asset Integrity Approach to
Achieve excellence in Process Safety
Ashish Kulkarni
Technical Centre Head
B.E. Petrochemical, TUV Certified CFSE
Bell Energy Middle East
www.bell-energy.com
Energy assurance for future generations

2. Energy assurance for future generations
Table of Contents
• Introduction
• Process Safety Excellence through Asset Integrity Management
• Asset Integrity Risk Management Process
• Asset Integrity Framework
• Phase wise Integrity Assurance
• Case Study: Hydrocarbon Gas Processing Plant
• Scope of the Case Study
• Methodology
• Identification of HSECES Category & Tag Level
• Establishing Performance Standards
• Updating Maintenance Job Plans
• Summary

3. Introduction
Sources:
1. UK HSE Key Programme 3 Asset Integrity Programme,
2. NASA System Failure Case Study, May 2013, Vol 7, Issue 4
Energy assurance for future generations

4. Energy assurance for future generations
Process Safety Excellence through Asset Integrity Management
• Piper Alpha disaster acted as the catalyst for development of
“Safety Case” regulations.
• The Safety Case regulations emphasize the need to maintain
integrity of HSE critical equipment and systems throughout
the asset lifecycle.
• It puts the responsibility of demonstrating that all risks are
reduced to as low as reasonable practicable (ALARP) on the
owner / operator.
• And requires that all those activities that prevent, mitigate or control major accidents at each phase are
identified, performed and verified.
• These requirements are fulfilled through the “Asset Integrity Management Programme” and Assurance is
provided through the “Safety Case”.
“Asset Integrity can be defined as the ability of an Asset to perform its required function effectively and
efficiently whilst protecting health, safety and environment.”

5. Asset Integrity Risk
Management Process
Sources:
1. OGP Report No. 415 – Asset Integrity – Key to Managing Major Incident Risks
2. ADNOC CoP V1-02 – HSEIA Requirements
3. ADNOC CoP V6-01 – Identification & Integrity Assurance of HSE Critical
Equipment & Systems
Energy assurance for future generations

6. Energy assurance for future generations
Asset Integrity Risk Management Framework
1. Laws, Regulation & Company Standards
What Drives the Requirement for Asset Integrity?
• National Laws, International Codes & Standards
• Company Regulations.
2. Communication & Consultation:
Who all should be involved in this Process?
• All stakeholders – Projects, Operations, Maintenance, Shareholders
• Content of communication based on the type & role of stakeholder
and according to the codes and standards
3. Risk Assessment
What Can Happen?
• Identify the risks, Analyse the consequences and frequency
• Evaluate the risk acceptability
4. Risk Treatment
What do we do?
• Involves considering all feasible solutions (engineering & procedural
controls) to reduce risk to ALARP
5. Monitoring and Review
What could we do better?
• Lessons Learnt
• Update in Technology
1. Laws, Regulations &
Company Standards
3.1 Risk
Identification
3.2 Risk
Analysis
3.3 Risk
Evaluation
4. Risk
Treatment
2.Communication&
Consultation
5.Monitoring&Review
3.RiskAssessment

7. Energy assurance for future generations
Phase Wise Integrity Assurance
Concept
Engineer,
Procure &
Construct
Install &
Commission
Operation
Modify /
Decommission
Phases in Asset Lifecycle
Phase 1: Design Integrity Phase 2: Technical Integrity Phase 3: Operational Integrity
Identify Barriers at System Level
• Process Containment
• Safety Instrumented Systems
• Fire Protection Equipment
Define Design Performance
Standards for each Barrier
• Max. Pressure, Temperature,
Stresses
• Time Factors
• Failure Modes & Effects
FEED
Identify Barriers at Equipment Level
• Pressure Vessel: V-101
• Pumps: P-206
• Fire Detector: F-001
Define EPC Performance Standards
for each Barrier
• Loading / Unloading method
• Storage / Stacking method
• Commissioning Procedure
Identify Barriers at Functional
Location
• Parent / Child Relationship or
• Geographical Location
Define Operate Performance
Standards for each Barrier
• Inspection requirements
• Maintenance requirements
• Frequencies

8. Case Study: Hydrocarbon
Gas Processing Plant
Source:
1. ADNOC GC Procedure for determining HSECES Ver 2, 2014
2. NOPSEMA Guidance Notes Rev 4, 2012
Energy assurance for future generations

9. Energy assurance for future generations
Scope of the Case Study
Facility Description
The Project consisted of three primary components:
• New facilities at an offshore Island to compress and dry hydrocarbon gases.
• A 30" high-pressure 120 km offshore pipeline to transport dried gas to processing
site.
• Processing site includes:
• Inlet separation and Stabilization unit,
• Debutanizer and Expanded storage facility,
• Tie in to existing system and Export pipeline
Scope:
• To identify HSECES at tag level
• Define Performance standards for each HSECES category.
• Updating Maintenance Job Plans

10. Energy assurance for future generations
Methodology
Review of COMAH / Bowtie
Analysis
Classify Equipment in to HSECES
Category
Updating HSECES Maintenance
Job Plans
Develop HSECES Performance
Standards
Outcome: HSECES
Categories
Outcome: Potential
for Optimization
Outcome: Tag Level
Demarcation
Risk Ranking
Outcome: Examination
Rigour

11. Energy assurance for future generations
Identification of HSECES Categories
Ignition Control
1. Hazardous Area
Classification
2. Certified Electrical
Equipment
3. Earthing & Bonding
4. Fuel Gas Purge
Process Containment
1. Pressure Vessels
2. Heat Exchangers
3. Rotating Equipment
4. Piping
5. Relief System
Detection Systems
1. Fire & Gas
Detectors
2. Pipeline Leak
Detectors
3. H2 Detectors
Protection Systems
1. Active Fire
Fighting
2. Passive Fire
Protection
3. Firewater ring
main
Shutdown Systems
1. ESD System
2. Blowdown
3. HIPPS

12. Energy assurance for future generations
Identification of HSECES at Tag Level
1. Decision Tree applied to each equipment tag
2. Classify equipment into HSECES and Non
HSECES
3. Route Numbers 1, 3, 4, 6, 8 and 9 are
HSECES
4. Route Numbers 2, 5, 7 and 10 are Non
HSECES
5. Create Spreadsheet and list classification for
each equipment tag
6. Link each equipment with Category based on
the Function of the HSECES
7. HSECES Functions are:
1. Prevention,
2. Control / Alarm,
3. Mitigation &
4. Emergency Response

13. Energy assurance for future generations
Risk Ranking
• An HSECES is associated with prevention, control, mitigation or recovery of a potential accident that is classified into Severity
4 – “Severe” or Severity 5 – “Catastrophic” or Severity 3 – “Critical” with Probability E – “Frequent 1 in 10 years”.
• The criticality is purely the risk if the HSECES fails to operate on demand. The higher the risk, higher the criticality.
• For e.g. A pressure vessel that ruptures catastrophically has severity 5 with a frequency determined from a QRA study or past
incidents to be Occasional. In this case its criticality is 5C and is more critical than an Atmospheric Tank that leaks with
severity 4 with similar probability.

14. Energy assurance for future generations
HSECES Identification Spreadsheet
Sr. No. EQUIP. No EQUIP. No. Description
HSECES
(Y/N)
Reason for HSECES
HSECES
Route
IMPACT CRITERIA
ADNOC RISK
MATRIX
P A E R Risk Ranking
1 41104052 ABSORBER COLUMN Y
Element contains flammable hydrocarbon. A catastrophic release from this element
could lead to injury to personnel
1 2C 4B 4C 2C 4C
2 41205733 GLYCOL STILL Y
Element contains flammable hydrocarbon. A catastrophic release from this element
could lead to injury to personnel
1 2C 4B 4C 2C 4C
3 41104053 STRIPPER COLUMN Y
Element contains flammable hydrocarbon. A catastrophic release from this element
could lead to injury to personnel
1 2C 4B 4C 2C 4C
8 70201863
DIFF PRESSURE
TRANSMITTER (FLOW)
Y
The element is part of shutdown / mitigation system designed for emergency
situations
3 4C 4B 2C 2C 4C
12 70230413
LEVEL TRANSMITTER
(DISP/GWR)
Y
The element is part of shutdown / mitigation system designed for emergency
situations
3 4C 4B 2C 2C 4C
9 70230410
LEVEL TRANSMITTER
(DISP/GWR)
Y
The equipment is designated to protect process equipment in order to avoid
catastrophic failure/injury
4 2D 4B 2C 1A 4B
14 70230415 LEVEL TRANSMITTER (GWR) Y
The equipment is designated to protect process equipment in order to avoid
catastrophic failure/injury
4 4C 4B 2C 2C 4C
20 44408125
1" x 2" PRESSURE SAFETY
VALVE
Y
The failure of element can cause Major Accident or it prevents, controls, or mitigate
a Major Accident
8 1B 4C 2C 2B 4C
21 44408126
1" x 2" PRESSURE SAFETY
VALVE
Y
The failure of element can cause Major Accident or it prevents, controls, or mitigate
a Major Accident
8 1B 4C 2C 2B 4C
22 44408127
1½" x 3" PRESSURE SAFETY
VALVE
Y
The failure of element can cause Major Accident or it prevents, controls, or mitigate
a Major Accident
8 1B 4C 2C 2B 4C

15. Energy assurance for future generations
Developing Performance Standards
“Parameters which are measured or assessed so that the suitability and effectiveness of each HSECES can be
assured or verified.”
FUNCTIONALITY
RELIABILITY
AVAILABILITY
SURVIVABILITY
Intended purpose of the HSECES in terms of its role in preventing, controlling or
mitigating the event in protecting people and assets.
The likelihood that a HSECES will perform its function on demand or when called
upon to do so.
Conditions necessary for a HSECES to remain functional during an incident until it has
performed its function.
INTERACTION / DEPENDENCIES Relationship between HSE Critical Equipment and Systems
Best Practices in Developing Performance Standards:
1. Performance Criteria shall cover all foreseeable operating
parameters that can cause failures
2. It shall cover Failure Modes including common causes due to
failure of other HSECES
3. Define Minimum Acceptance Criteria for each function that
can be measured

16. Energy assurance for future generations
Performance Standard Template
Risk Reduction Measure: Prevention Control Mitigation Life Cycle Phase
HSECES Group: Structural Integrity Detection Systems Shutdown Systems Phase 1:
Ignition Control Protection Systems Emergency Response Phase 2:
Process Containment Life Saving Phase 3:
HSECES Reference No.:
HSECES Criticality:
Doc Ref.
Doc Ref.
Doc Ref.
Inter Dependency
System Reason
Task Task
Survivability
Event Criteria
Assurance Verification
Reliability / Availability
Function No. Functional Criteria / Guidance
Assurance Verification
Task / Confirmation Task
HSECES Extent:
Function No. Function Functional Criteria / Guidance
Assurance Verification
Task / Confirmation Task
System: Revision No.:
HSECES Goal: To provide an early warning of drifting flammable gas clouds in the Storex Tank farm area.
HSECES Performance Standard Template
HSECES: Performance Standards Ref.:
Site: Performance Standards Owner:
Plant: Signed off:
Risk ReductionMeasure: Prevention Control Mitigation Life Cycle Phase
HSECES Group: Structural Integrity DetectionSystems ShutdownSystems Phase1:
IgnitionControl ProtectionSystems Emergency Response Phase2:
Process Containment LifeSaving Phase3:
HSECES ReferenceNo.:
HSECES Criticality:
DocRef.
DocRef.
DocRef.
Inter Dependency
System Reason
Task Task
Survivability
Event Criteria
Assurance Verification
Reliability/ Availability
Function No. Functional Criteria / Guidance
Assurance Verification
Task/ Confirmation Task
HSECES Extent:
Function No. Function Functional Criteria / Guidance
Assurance Verification
Task/ Confirmation Task
System: RevisionNo.:
HSECES Goal: Toprovideanearly warningofdriftingflammablegas clouds intheStorex Tank farm area.
HSECES Performance Standard Template
HSECES: PerformanceStandards Ref.:
Site: PerformanceStandards Owner:
Plant: Signedoff:

17. Energy assurance for future generations
Updating Maintenance Job Plans
Align Assurance Tasks with Maintenance Strategy
• HSECES performance assurance tasks can be integrated with normal Maintenance Job Plans
where applicable / logical.
• HSECES performance assurance task frequency is derived from Risk & Reliability
Management Results, where RRM results are not available, Design Standards or formal safety
studies requirements are followed.
Optimization Techniques:
• Performance assurance tasks can be combined in the same Planned Maintenance Routine but
the operation shall be identified as an assurance task.
• Performance assurance tasks on several HSECESs can be combined into the same Planned
Maintenance Routine to optimise planning and execution effort.

18. Summary
Energy assurance for future generations

19. Energy assurance for future generations
Summary
Advantages
• Approach focusses on prevention of Major Accident Hazards;
• Prioritizes on critical equipment & systems;
• Integrates with Maintenance Strategies and makes for a robust maintenance regime;
• Optimizes planning & execution efforts.

20. About Us
Energy assurance for future generations

21. Energy assurance for future generations
About Us

22. Thank you