The Practical Application of Process Safety Principles to Determine and Monitor Asset Integrity of Oil and Gas Facilities

Abstract

Abstract This paper discusses the differences between Process Safety Management and Asset Integrity Management. It demonstrates how Asset Integrity is defined and managed simultaneously across a wide range of asset types –oil and gas, offshore production, onshore terminal, fixed platform, FPSO, NUI, new and mature assets. The process is based on simple yet established principles which give clarity to areas that require attention. At its centre is a tool which defines the current vulnerability of the assets against engineering, production, maintenance, systems and human factors parameters. The vulnerability of an asset is ‘benchmarked’. The information is displayed in different formats to meet the requirements of each level of risk management and accountability in the Duty Holder organization. This accelerates understanding of the current risks against Major Accident Hazards as both single and combined events. Remedial actions can be prioritized and resourced. Senior Management can interrogate the process to a detailed level in order to challenge the effectiveness of the interventions. The process is based on the Barrier Model and uses Process Safety Performance Indicators selected to monitor Asset Integrity based on the company’s experience of managing offshore oil and gas assets. Each barrier is different and has an appropriate weighting. Calibration against a standard defines the strength of the barriers which in combination should prevent Major Accident Hazards on a site. Lagging and Leading PSPI are treated as ‘Holes’ and ‘Cracks’ in the barriers respectively. Weekly performance against the PSPI is recorded and used to derive the Vulnerability Index for the asset for that week. After any event against a PSPI, a simple Root Cause Analysis is carried out to determine which individual barriers were involved. Combined Risk is displayed in a number of different formats. The process is adaptable, and can be scaled to suit a wide range of different types and size of facilities. It can be adapted for use in Process Safety Management This process has evolved over three years. Asset Integrity Management is now imbedded in the organization. The implementation journey has not been easy. The paper gives an insight into the traction factors on this journey. Asset Integrity is a status; you either have it or do not have it. Process Safety Management may deliver Asset Integrity. Asset Integrity Management is specifically designed to deliver Asset Integrity on a facility. Process Safety Management has the benefit of being applied to a wider range of industries and size of facilities. Appendix D discusses the above and the company’s journey in terms of Asset Integrity Management up to 2008.