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issue. In reality, leaking equipment
often results in downtime or other
production impacts. Therefore, leaking
equipment is unreliable equipment
(Figure 1).
This concept of an asset-management
program that addresses a
broad spectrum of risks is not new
and is provided in BS ISO 55000 series,
Asset Management. One of the
requirements of this ISO standard is
to identify key stakeholders and then
identify each group's risk. An obvious
application of this requirement
would be to include all safety risks
(process and occupational), environmental
risks, economic risks and
other operational risks. This standard
then outlines requirements for asset
management programs that address
all identified risks. Holistic asset
management can begin by combining
MI and reliability programs into a
single framework.
Blending programs
Synergies between the two approaches
relate to managing the
risks associated with asset degradation
and failures. There are also many
synergies at the program-design,
implementation and execution levels
of these two programs. A key aspect
of both programs is the implementation
of management systems (the
commonly used term in the processsafety
world) or business processes
(the commonly used term in the reliability
world). Asset management
systems define the overall asset management
policies and objectives and
the systems and processes needed
(who, what and how) to implement
the asset management policies and
achieve the program objectives.
ISO 55001 addresses the elements
of an asset management program (the
" what " ) and ISO 55002 provides specifics
regarding the " how " of the asset
management program. Most holistic
reliability programs include their management
teams in core elements,
such as work management, inventory
management, equipment maintenance
plans (such as predictive and preventive
maintenance plans) and implementation
of the computerized maintenancemanagement
system (CMMS).
So what are the common attributes
between ISO-55000, MI and
36
reliability-program management systems?
Looking at Table 1, it can be
seen how plants can leverage and
integrate activities from these three
programs with a few examples of the
common elements from each of these
three programs. While the strategic
and conceptual similarities between
reliability and MI programs are interesting,
the important synergies are related
to the tactical activities that influence
the day-to-day implementation
of these two programs.
Synergizing examples
Considering the example of a process
pump in hazardous chemical service,
two potential areas of synergy between
asset reliability and MI activities include
common reliability activities, such as
operator walks (visual inspection) and
vibration analysis. Both of these practices
are also MI-related activities because
they help to detect and prevent
loss-of-containment events. Another
example is instrumentation and control-system
reliability practices, such as
periodic sensor calibration and functional
checks. When these practices
are applied
to
safety-critical
instruments
and controls (such as safety instrumented
systems), MI requirements
are incorporated.
The common MI practices for fixed
equipment, such as a shell-and-tube
heat exchanger or pressure vessel,
would include API-type inspections
and testing, including visual inspection
and pressure boundary-thickness
non-destructive testing (NDT).
Leaks in a heat exchanger or pressure
vessels during operation can
result in unplanned downtime (which
is a reliability impact). Also, these API
inspections and tests help predict the
end-of-life for these equipment items,
which allows for planning and proactive
equipment replacement (which
is a reliability issue). There are also
common reliability practices related
to managing the condition of heat-exchange
fluids (such as cooling water)
and the periodic cleaning of heat-exchange
surfaces. These activities can
reduce thinning and degradation of
the shell and tube and lower the probability
of a process safety event, such
as loss of containment.
Asset data
A key area between MI and reliability
programs is asset data management,
where both programs require compilation,
verification and management
of asset data to be effective. This
data-management effort involves developing
a master asset list and then
populating this list with relevant assetrelated
data.
Master asset lists typically involve
the following elements:
1. Reviewing the piping and instrumentation
diagrams (P&IDs) to identify
assets
2. Compiling asset information from
engineering, maintenance and operational
files and records
3. Performing field walk-downs to
verify the asset list and collecting
missing data
4. Establishing the master asset list
and data in the data-management
systems
5. Organizing and associating the
relevant data (including drawings
and documents from original equipment
manufacturers) in the datamanagement
systems
While the steps for developing the
master asset management list for MI
and reliability purposes are similar,
each program has slightly different
TABLE 1. TYPICAL COMMON ELEMENTS OF ISO 55000, RELIABILITY AND MI PROGRAMS
ISO 55000
Reliability program
Asset management objectives (ISO 55002 - 6.2.1 [3])
Asset portfolio
Asset information (ISO 55002 - Section 7.5 [3])
Asset management plan - Operational and maintenance
plans (ISO 55002 - Section 6.2.2 [3])
Corrective actions: both short- and long-term corrections
(ISO 55002 - Section 9.2.2.1 and 10.2.1 [3])
Asset performance;
lifecycle costs; health,
safety and environment
Master asset list
Asset records
Reliability strategy
Work management
MI program
Health, safety and
environment
MI-covered
equipment LL
Equipment processsafety
information
Inspection and test
plans
Equipment deficiency
management
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