KP4: Ageing and Life Extension - Inspection Template – Pipeline Systems
INSTALLATION or DUTYHOLDER / DATES(S) / IMT and INSPECTOR(S)Key Persons interviewed / Company / Position
Summary of Inspection Traffic Lights / Red / Amber / Green / W
6 / 5 / 4 / 3 / 2 / 1 / 0
Section A: Ageing and Life Extension (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: /
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 described
· References to codes, standards & guidance, for example:
o OSD Info sheet 4/2009;
o Plant Ageing HSE RR 509;
o Energy Institute ‘Framework for monitoring the management of ageing effects on safety critical elements’
Pipeline Supplementary Questions:
The duty holder shall demonstrate the existence of a clear and appropriate corporate policy on ALE.
A-1. Is the corporate policy on ALE sufficient in its scope and breadth and cover pipelines within its focus?
A-2. To what extent is the corporate ALE policy embedded within the pipeline safety/integrity management policies and systems?
A-3. How do pipeline ALE issues contribute to the safety case Thorough Review process?
The duty holder shall demonstrate general understanding of pipeline related ALE issues and that they form an essential component of the pipeline integrity management system (PIMS).
A-4. Describe the PIMS policy approach to managing and assessing the ageing processes and the need to link inspection requirements to these?
A-5. How does the PIMS policy address pipeline life-extension?
A-6. What ALE responsibilities/involvement do senior managers have in the policy?
The duty holder shall demonstrate that the pipeline PIMS is fit-for-purpose for ALE and adopts a cyclical process comprising planning, implementation and evaluation.
A-7. Give a brief overview of the key policies, systems, processes and documents covering the overall Pipeline Integrity Management framework and how they specifically focus on ALE; eg PIMS, MAPD
Section A: Ageing & Life Extension – Policy and Leadership
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NON-COMPLIANCE / SIGNIFICANT NON-COMPLIANCE / GENERAL
NON-COMPLIANCE / PARTIAL COMPLIANCE / GENERAL COMPLIANCE / GENERAL COMPLIANCE / NOT INSPECTED
Court proceedings recommended
6 / Enforcement Notice Served
5 / Letter & changes made to intervention
4 / Letter
3 / Verbal advice
2 / No findings
1 / 0
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
Pipeline Supplementary Questions:
The duty holder shall demonstrate that an effective management structure is in place for delivering the pipeline ageing & life-extension (ALE) policy.
B-1. Is there adequate description of the PIMS organisation structure and key roles within the policy documentation? Is there specific ALE focus?
B-2. What use of internal specialist skills/knowledge on ALE issues for pipelines and how is this managed?
B-3. To what extent are contractors involved and how are they selected and assessed for competency and monitored for performance?
B-4. Is the pipeline ALE policy underpinned by staff involvement and participation? Is there an ongoing mechanism in place for staff feedback?
B-5. What provisions are in place to retain operational and maintenance records? Is there a plan in place to convert paper records to digital records?
The duty holder shall demonstrate that the need for competency in ALE and pipeline integrity management (PIM) is recognised and incorporated within the ALE policy.
B-6. How does the duty holder identify and maintain sufficient and appropriate competencies to identify ageing mechanisms, evaluate the extent of ageing, and implement mitigation measures for pipelines?
B-7. How do those responsible for managing, inspecting & maintaining pipelines ensure adequate understanding of ALE issues and remain aware of the key indicators, signs and symptoms to show that a plant is ageing?
B-8. How are key pipeline issues, signs or symptoms communicated to operations or maintenance personnel so they are aware of what to be alert to as indicators of ageing plant?
B-9. Who is responsible for conducting/approving pipeline condition assessments and how is their ongoing competency reviewed/validated?
B-10. Who is responsible for approving pipeline life-extension studies and for determining/approving any limitations on future use? Are there defined competency standards for this role? Any evidence of review?
Section B: Ageing & Life – Organisation
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NON-COMPLIANCE / SIGNIFICANT NON-COMPLIANCE / GENERAL
NON-COMPLIANCE / PARTIAL COMPLIANCE / GENERAL COMPLIANCE / GENERAL COMPLIANCE / NOT INSPECTED
Court proceedings recommended
6 / Enforcement Notice Served
5 / Letter & changes made to intervention
4 / Letter
3 / Verbal advice
2 / No findings
1 / 0
Section C: Ageing & Life Extension – Planning and Implementation
Principal Questions:
1. What steps are being taken to ensure the implementation of the ALE policy?
2. Explain how the Integrity Management System captures ageing issues.
Benchmarks sought in replies:
· Explanation of how equipment subject to ageing is selected and identified
· Review of the suitability of the performance standards
· Assessment of operation beyond design life
· 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
Pipeline Supplementary Questions:
The duty holder shall demonstrate that an effective inspection and maintenance plan is in place.
C-1. What is the basis of the inspection plan (e.g., risk-based or time-based)? Has the regime changed to risk-based since the plant was constructed?
C-2. Has any part of a pipeline experienced recurring defects, or increasing trends of unplanned work and breakdowns? Evidence to manage these aspects?
C-3. Are there arrangements in place to identify plant & equipment that is approaching or has exceeded its original design life?
C-4. Does the duty holder utilise a third-party integrity management organisation? If so, to what extent is the duty holder involved with the inspection planning and implementation process?
C-5. Is there a clear system in place by which the inspection plan is implemented with mechanisms to handle deviations from the inspection plan?
The duty holder shall demonstrate that plant & equipment that is difficult to inspect or maintain has been identified.
C-6. Any evidence of measures introduced to manage difficult to inspect or maintain structural plant & equipment? eg non-piggable; riser in caisson etc
C-7. Evidence of out-of-date or obsolescent equipment identified and managed?
The duty holder shall demonstrate Ageing and Life Extension issues in practice and that life extension/ fitness-for-purpose evaluations are sufficiently detailed.
C-8. Any evidence of pipeline life extension life proposed or implemented? Has it followed formal procedures and been formally recorded?
C-9. Any evidence of damage or ageing/deterioration to critical plant, equipment or components being identified and remedial measures put in place?
C-10. Has there been a change-of-use that violates the original design or previous integrity assessment? How has that been assessed/managed/recorded?
Section C: Ageing & Life Extension – Planning and Implementation
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NON-COMPLIANCE / SIGNIFICANT NON-COMPLIANCE / GENERAL
NON-COMPLIANCE / PARTIAL COMPLIANCE / GENERAL COMPLIANCE / GENERAL COMPLIANCE / NOT INSPECTED
Court proceedings recommended
6 / Enforcement Notice Served
5 / Letter & changes made to intervention
4 / Letter
3 / Verbal advice
2 / No findings
1 / 0
Section D: Ageing & Life Extension – Measuring Performance /
Principal Questions:
1. How does senior management know that the risks arising from ALE are being effectively controlled?
2. Describe the performance indicators used to demonstrate the current condition of the installation plant and equipment.
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
Generic Supplementary Questions:
The duty holder shall demonstrate an adequate understanding and knowledge as to the current status of integrity of pipelines & associated equipment.
D-1. What system/processes does the duty holder adopt to review and demonstrate pipeline current condition?
D-2. To what extent does this review process relate to pipeline design/service life and contribute to an assessment of remaining life?
The duty holder demonstrates an adequate system by which performance is measured.
D-3. What specific key performance indicators (KPIs), 'traffic lights' or similar are used to review pipeline condition? Can the duty holder demonstrate adoption of appropriate leading and lagging indicators?
D-4. Describe how the inspection techniques are determined to be appropriate for the detection of ageing or deteriorating pipeline performance?
D-5. Do maintenance procedures/KPI’s consider or identify the need for a more detailed inspection if a period of life extension is to be justified or if deterioration from an ageing mechanism is identified?
D-6. Evidence of evaluation of revised/new codes, standards, guidelines, etc., and adapting inspection and maintenance, etc., where necessary?
D-7. How do lessons learned from incidents and pipeline related failure trends feed into the process?
The duty holder shall demonstrate that a process is in place to monitor deterioration
D-8. What mechanisms are in place to record information relating to ageing?
D-9. Have any pipelines or associated equipment been identified as ageing? If so, what measures are being taken to manage these issues?
D-10. How is the condition of pipelines and associated equipment approaching or exceeding original design life identified?
D-11. Any evidence of any pipelines or associated equipment being identified from monitoring when approaching original design/service life?
D-12. Does the duty holder review operation and maintenance histories that identify pipelines that may have been subject to ageing processes?
Section D: Ageing & Life Extension – Measuring Performance
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NON-COMPLIANCE / SIGNIFICANT NON-COMPLIANCE / GENERAL
NON-COMPLIANCE / PARTIAL COMPLIANCE / GENERAL COMPLIANCE / GENERAL COMPLIANCE / NOT INSPECTED
Court proceedings recommended
6 / Enforcement Notice Served
5 / Letter & changes made to intervention
4 / Letter
3 / Verbal advice
2 / No findings
1 / 0
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
· Audit findings reviewed by senior management
· Management improvements identified
· SCE verification process addresses ALE issues
Generic Supplementary Questions:
The duty holder shall demonstrate that a process is in place to review and audit findings and to implement continuous improvement with respect to pipeline ageing.
E-1. How frequently are pipeline policies, strategies and documents reviewed and up-dated and by whom? eg PIMS, MAPD Any evidence of recent changes?
E-2. Is there any evidence of improved standards, lessons learned and trends of incident, accident and near-miss data being used to improve PIMS? Any evidence of identification and management of obsolescence?
E-3. What is the frequency and scope of audits of PIMS, including ALE issues? When was the last audit undertaken? What evidence of findings/issues?
E-4. Who performs the pipeline audits? Internal or third-party?
The duty holder shall produce a 'pipeline statement of integrity' as produced by the technical authorities for senior management.
E-5. What involvement do senior managers have with the ‘statement of integrity’ process? Are they on the distribution list? Evidence they’re aware of condition?
E-6. How are recommendations to senior management made with respect to the level of resources required to maintain integrity?
The duty holder shall demonstrate that the verification process addresses adequately the potential loss of pipeline integrity arising from deterioration associated with ALE.
E-7. What reference is made in the corporate verification scheme to ALE?
E-8. Are SCE performance standards on the loss of integrity from deterioration associated with pipeline ageing and life extension available?
E-9. Any evidence that the verification process has identified any deterioration from ageing mechanisms or demonstrated that integrity has not been compromised by ageing mechanisms? Any evidence of associated improvements?
The duty holder shall demonstrate that a process is in place to consider third party pipelines and pipeline areas out with the 500m zone
E-10. Any evidence of cooperation on audit and reviews in these areas? eg when connected to 3rd party pipeline systems or pipelines on 3rd party installations?
Section E: Ageing & Life Extension – Auditing and Reviewing Performance
Onshore Management:
Offshore Operations:
HSE Comments:
HSE Action taken:
Traffic Light Score
SERIOUS
NON-COMPLIANCE / SIGNIFICANT NON-COMPLIANCE / GENERAL
NON-COMPLIANCE / PARTIAL COMPLIANCE / GENERAL COMPLIANCE / GENERAL COMPLIANCE / NOT INSPECTED
Court proceedings recommended
6 / Enforcement Notice Served
5 / Letter & changes made to intervention
4 / Letter
3 / Verbal advice
2 / No findings
1 / 0
August 2011 V1.0 Page 1 of 11