The primary objective of the APMA was to provide a detailed integrity and reliability review of all the assets in the plant and develop action plans to ensure safe and reliable operations of the plant. The study covered multiple technical disciplines, a review the work processes (systems and procedures), and the current health of all static, rotating, electrical, instrumentation, and process control equipment/assets.
INTEGRITY MANAGEMENT REVIEW FINDINGS
This APMA identified and highlighted failures and system gaps that need to be bridged to prevent occurrence/re-occurrence of the failures and gaps. The structured review of the Company Plant Utility Units’ Asset Management Program was done with an emphasis on ensuring it was aligned to current industry “best practices,” to identifying potential gaps, and provide the basis for establishing short- and long-term improvement strategies. The process was carried out by using a combination of questionnaires, staff interviews, and a review of existing documentation (policies, procedures, and maintenance history e.g., monitoring and repair data).
The key areas of the review were:
• Confirmation of the key drivers for improvements in Asset Management, e.g.,
• Health, Safety, and Environmental (HSE) commitments
• Business requirements
• Staffing requirements and utilization
• Identifying and highlighting areas of best-practice
• Identifying potential shortfalls in the existing Asset Management Program, e.g.,
• Policies, procedures, and guidelines
• Organizational issues
• Record keeping quality assurance, activity scheduling, etc.
• Provide recommendations, where appropriate, for improvements to the Asset
The review addressed the following topics, which typically form part of Asset Management
• Policy and Strategic Objectives
• Organization and Resources
• Risk Management
• Planned Equipment Maintenance
• Work Selection/Execution
• Preventive Maintenance (PM)
• Reliability and Maintenance Improvement
• Inspection and Monitoring
• Rotating Machinery
• Static Equipment/Piping
• Operations Practice
• Design and Construction for Modifications
• Management of Change (MOC)
• Information Management
• Staff Competency
• Third-party Services
• Anomalies, Repairs, and Failure Analysis
The findings obtained from addressing these topics indicated that some were pertinent to Company Corporate Maintenance and Engineering functions or some were specific to the Plant, maintenance, inspection, operations, and engineering functions. The findings are tabulated in Tables 3-1 through 3-20. The findings summarized in the following subsections are supported by those tables.