Ray-Goodfellow.

1. Incorporating an Asset
Integrity Program into the
Design Stage
of Projects

2. What is Asset Integrity
 Asset Integrity is an effective system for
managing the integrity of equipment, piping and
pipelines throughout the full lifecycle:
 design
 construction & installation
 operation
 maintenance, (repairs, alterations)
 integrity assessments
 decommissioning
 Developing and implementing an Asset Integrity
program at the design stage supports lifecycle
reliability and operability

3. What is Asset Integrity
 Regulatory Requirements (ABSA/CSA/EUB/)
 Pressure Equipment Integrity Management System
(PEIMS)
 Pipeline Integrity Management Program
 Key elements include:
 Risk assessments
 Degradation Circuits
 Material selection
 Condition monitoring location (CML) selection
 Inspection, Mitigation, Monitoring
 Data management
 Training programs

4. What is Asset Integrity
 Typical Equipment within Scope:
 Boilers and heaters
 Pressure vessels (including Pressure relief devices)
 Pressure piping
 Tanks
 Non-pressure static equipment
 Non-pressure piping
 Pipelines
 Not in Scope
 Structural
 Rotating equipment
 Electrical

5. Overview
 Why:
 What is the value of incorporating Asset Integrity into
the design stage of a project?
 How:
 What are the key activities at each stage of the
project?
 Deliverables:
 What are the deliverables at each stage of the
project?

7. Why
 De-ethanizer overhead gas
line – erosion corrosion
failure downstream of mixing
point
Humber Refinery Fire, Health Safety Executive (HSE) Report
http://www.hse.gov.uk/offshore/information.htm

8. Why incorporate Asset Integrity into
the design stage of a project
 The goal of each project is to create a business asset
that performs its intended function, is safe,
environmentally sound and reliable.
 The project is expected to be executed within the planned cost
and schedule
*“ I can’t emphasize enough that you’ve got to get this right.
You got to get this right. Because when you finally lock the
scope, you’re stuck with it for 30, 40, 50 years, so you better
not have any regrets when you start building it and running it
that you didn’t get it right”
~Neil Camarta
*Petro-Canada Investor Day: Fort Hills—Oil Sands Engine of Growth, Neil Camarta, Senior Vice-President, Oil
Sands

9. “You got to get this right”
 Incorporate lifecycle asset integrity into the
design
 Have a positive impact:
 for the project – efficient project execution
and optimize capital costs
for the operation- improve reliability and
operability

10. Incorporate lifecycle asset integrity into
the design
 Make well thought out
decisions to meet project
and operations objectives
 Good decisions include:
 Involving the right people
 Having a structured process
to guide decision making
 Maintaining good
documentation

11. Incorporate lifecycle asset integrity
into the design
 Increased upfront engineering can:
 Support quality decisions regarding CAPEX (design
mitigation) and OPEX (operational mitigation)
 Provide clarity and direction that reduces time in
detailed engineering
 Reduce rework during fabrication and during
operations
 Meet operational reliability expectations for long term
plant life

12. Trend in Industry
 Understanding of the importance of
incorporating Asset Integrity into the design
stage is increasing due to serious failures in the
refinery, petrochemical and pipeline industry
 Major corporations now require risk assessments at
the design stage.
 Regulator requires the effective systems for managing
the integrity of their pressure equipment throughout
its full lifecycle which includes design, construction
and installation.

13. How
 Incorporate asset integrity activities into key
phases of the project
 Identify key project objectives, development phases,
milestones and hold points
 Utilize defined processes (i.e. Risk Base Inspection)
to make decisions
 Supply defined deliverables at each stage of the
project
 Recognize, understand, and quantify the impacts and
values added from asset integrity activities

14. Key activities and deliverables at
each stage of the project
 Companies have multi step project
management processes
1. Select Alternatives
2. Front End Engineering
3. Detailed Engineering
4. Fabrication and Construction
5. Commissioning
6. Turn Over to operations

15. 1. Select Alternatives
 Key Processes
Design Basis Risk Assessment
Lessons Learned Study
 Key Deliverables
Asset Integrity design philosophy report
Lessons learned report
Technical work book with all supporting
information. (dynamic document)
 The work book will form the basis of additional risk
assessments and the integrity manuals for the
operating facilities

16. 1. Select Alternatives
 Impact
 Business basis for integrity
management strategy
 Risk based decisions that
consider full asset lifecycle
 Design mitigation
 Alloy’s, coatings, equipment
design, process changes
 Operational mitigation
 Inhibition, process control,
inspection, monitoring, run to
failure
 Alternative selection considers
potential degradation
mechanisms and other
hazards

17. 2. Front End Engineering
 Key Activities
 Risk Assessment
 Incorporate lessons learned
 Development/Updating of Standards
 Management of Change
 Key Deliverables
 Scope and budget includes asset integrity and QA
work
 Technical work book with all supporting information.
 New or revised specifications
 Documented basis of integrity related design
decisions

18. 2. Front End Engineering
 Impact
 Scope and costs for integrity
related work are included in
project budget
 Determine first planned
shutdown
 Equipment isolation and
inspection plan
 Design mitigation
 i.e. select materials and design
 Operational mitigation
 i.e. select mitigation and
monitoring strategy

19. 3. Detailed Engineering
 Key Processes
 Assessment of deviations from initial design
 Previous Risk Assessment methodology can be used
 Materials selection report and diagram (MSD) reviews
 P&ID reviews
 Development/Implementation of quality assurance program
 Key Deliverables
 Reports or recommendations on specific technical issues
 Equipment Integrity Manuals
 Based on technical work books
 Degradation circuits
 Document the basis of design decisions
 Incorporates information from reports or recommendations on specific
technical issues
 Foundation of RBI and overall asset integrity program
 Incorporate EPC Information
 Condition Monitoring Location (CML) selection
 Corrosion monitoring locations
 QA issues

20. 3. Detailed Engineering
 Impact
 Provide technical input at
project reviews, hold points,
and milestones
 Capture the technical basis
and rational behind material,
mitigation, monitoring and
inspection decisions
 Understanding the rational
allows more effective
management of future changes
(personal and process)
 3D Modeling can be used for
selection of CML’s, corrosion
monitoring locations, etc.

21. 4. Fabrication and Construction
 Key Activities
 Quality assurance and Quality control
 a key aspect of asset integrity
 Vendor audits and reviews
 Assessment of deviations from design
 Key Deliverables
 Updated equipment integrity manuals
 Baseline CML survey on critical equipment and piping
completed
 Start populating equipment data base

22. 4. Fabrication and Construction
Impact
Final product
meets design
specifications
Have base line
data

23. 5. Commissioning
 Key Activities
 Assessment of deviations from design
 Regulatory requirements prior to start up
 Plan for start up activities
 Key Deliverables
 Installation Inspections compete
 PSV’s serviced
 Equipment integrity manual complete
 Equipment database is populated with new equipment
 Baseline TML complete on critical equipment and piping
 Complete training for critical tasks

24. 5. Commissioning
 Impact
 All critical tasks have
been completed prior
to start up
 Installation inspections
and PSV servicing
 Inhibition programs in
place
 Monitoring programs in
place
 Training on procedures
completed

25. 6. Hand Over to Operations
 Key Processes
 Training
 Key Deliverables
 Equipment Integrity Manuals
 Documentation of deviations from design
 Populated database
 Mitigation and monitoring plan
 Maintenance planning
 Long term training program

26. 6. Hand Over to Operations
 Impact
 A business asset that is safe, environmentally sound and reliable