Asset Integrity Management Assessments

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The parts of the MI System Model are:

Inputs - Inputs to MI are:

• existing equipment items to be incorporated into MI including their historic design, performance, and repair data
• new equipment items added later to the process including their design data
• Equipment items are included in MI because coverage is required for compliance with governmental regulations required because the equipment has an impact on key business indicators other than safety

Procedures - MI is defined, implemented, and managed by the written and approved procedures included in the MI Manual and site-specific installation procedures. All procedures should be based on:

• regulatory requirements or governmental procedures
• recognized and generally accepted good engineering practices, such as API, ANSI, SAE, and NFPA standards and practices
• site safety requirements or manuals
• site maintenance practices and procedures
• site design or engineering standards

Facilities/Equipment - The facilities and equipment that drive the MI process include:

• document management system for approval, issue, storage, distribution, and revision of controlled procedures and drawings
• information management system for controlling maintenance data and records, including reports generated within the MI process
• quality assurance system to manage maintenance materials, spare parts, and replacement equipment to ensure they meet the design intent and are suitable for use when needed
• well-maintained tools and equipment
• inspection and test equipment that is in good repair and certified if necessary
• qualified contractors to perform various maintenance, inspection, and testing tasks

Training/Knowledge - Properly trained personnel perform their assignments more efficiently, thereby reducing maintenance costs.

The training for people working to maintain equipment integrity and reliability includes:

• Process Overview Training so they understand a general overview of the equipment, process materials, and area safety information for the area in which they will work
• Administrative Training so they understand corporate, site, and area policies, practices, and procedures necessary to perform their jobs safely and efficiently. This includes MI training
• Regulatory Training so they understand the applicable regulations
• Task Training so they are qualified to perform the tasks associated with their job

Performance Standards - Performance standards describe desired or optimum performance, and are used to develop metrics that measure actual performance against those standards.

Typical performance standards are:

• compliance with all regulations
• no injuries or safety incidents
• no leakage of hazardous materials
• optimum equipment availability
• first quality product

Outputs - The outputs of MI are:

• Equipment whose performance is continuously improving toward optimum. The revised Equipment Plan becomes the input to the Plan step the next time work is performed.
• Data that can be used to measure actual performance and to make step change improvement by the elimination of defects

The Value of System Design - Many maintenance systems focus on one or two of the elements in the continuous improvement model and pay little attention to the others. As a result, maintenance performance suffers and production costs are higher putting an organization at a competitive disadvantage.

Typical omissions addressed in AOC's MI model, for each element include:

• Inputs - design and historic information not available to personnel
• Process - focus on fast repairs with little attention to planning and scheduling, evaluating results, or updating (improving) the maintenance system
• Performance Standards - undefined performance standards or using performance standards that have little significance as a measure of maintenance performance
• Procedures - procedures not in place or uncontrolled
• Facilities/Equipment - no system in place to manage the quality of support facilities and maintenance equipment

Training/Knowledge - no focused training process to deliver the specific training needed by each employee

• Output - as a result of the shortcomings of the other elements, the equipment does not perform as it should and little improvement is attained.