Dealing with Aging Process Facilities and Infrastructure

Intro -- Dealing with Aging Process Facilities and Infrastructure -- Table of Contents -- List of Tables -- List of Figures -- Acknowledgments -- Preface -- 1 Introduction -- 1.1 Overview -- 1.2 Purpose -- 1.3 Aging: Concerns, Cause and Consequences -- 1.4 How Aging Occurs -- 1.4.1 Metallic Corrosion -- 1.4.2 Corrosion Under Deposits -- 1.4.3 Corrosion Under Insulation and Fireproofing -- 1.4.4 Manufacturing Defects -- 1.4.5 Excessive Wear and Tear -- 1.4.6 Fatigue -- 1.4.7 Non-Metallic Aging -- 1.4.8 Aging of Physical Structures -- 1.4.9 Process Chemicals Aging -- 1.4.10 Aging of Specialized Equipment -- 1.4.11 Obsolescence -- 1.4.12 Redundancy -- 1.4.13 Brownfield Construction -- 2 Aging Equipment Failures, Causes and Consequences -- 2.1 Aging Equipment Failure and Mechanisms -- 2.2 Consequences of Aging Equipment Incidents -- 2.3 Mechanical Failure of Metal -- 2.3.1 Deformation of Materials -- 2.3.2 Ductile vs Brittle Fracture -- 2.3.3 Metal Fatigue -- 2.3.4 Corrosion/Erosion -- 2.3.5 Warning Signs -- 2.3.6 Aging Equipment Failure Case Studies -- 2.4 System Functional Aging -- 2.4.1 Aging Equipment Failure Mechanisms -- 2.5 Aging Structures -- 2.5.1 Warning Signs -- 2.5.2 Aging Structure Case Study -- 3 Plant Management Commitment and Responsibility -- 3.1 Promoting Site Safety Culture -- 3.2 Management Challenges -- 3.3 Monitoring Aging Process and Measuring Performance -- 3.4 Human Resources Requirements -- 3.5 Planning for Equipment Retirement and Replacement -- 3.6 Appreciating the Importance of Aging Infrastructure to the Business Enterprise -- 3.6.1 Structural Assets -- 3.6.2 Roads -- 3.6.3 Impoundments and Dikes -- 3.6.4 Fire Water, Cooling Water and Sewers -- 3.6.5 Electrical Distribution Systems -- 3.6.6 Marine Facilities -- 3.6.7 Other Process Facility Infrastructure -- 3.7 Addressing Aging Infrastructure in Decision Process.

3.7.1 Questions Executives Need to Ask -- 3.7.2 Mergers and Acquisitions -- 4 Risk Based Decisions -- 4.1 Risk Management Basics -- 4.1.1 Risk Ranking -- 4.1.2 Risk Mitigation Controls -- 4.2 Risk Based Decisions -- 4.2.1 When to Apply Risk Based Decisions -- 4.3 How to Apply Risked Based Decisions -- 4.3.1 Determine Hazard Scenarios -- 4.3.2 Assess Consequences -- 4.3.3 Assess Likelihood -- 4.3.4 Determine Risk -- 4.3.5 Develop Risk Mitigation Controls -- 4.3.6 Implement Risk Controls -- 4.3.7 Information Required for Risk Based Decisions -- 4.3.8 Documentation of Risk Based Decisions -- 4.4 Embracing Risk Based Management -- 4.4.1 Alignment of Management and Operations with Risk Based Decisions -- 4.4.2 Incorporate Corporate Responsibility and Economic Value -- 4.5 Dealing with Unexpected Events -- 4.6 Risk Based Decisions Success Metrics -- 5 Managing Process Equipment and Infrastructure Lifecycle -- 5.1 Lifecycle Stages -- 5.2 Asset Lifecycle Management -- 5.2.1 Management Strategy Development -- 5.2.2 Organizational Design -- 5.2.3 Long-Term Asset Planning -- 5.3 General Topics -- 5.3.1 Manage by Operational Integrity -- 5.3.2 Managing Change During Lifecycle -- 5.3.3 Orphaned Assets -- 5.3.4 Disrepair of Assets -- 5.3.5 Extending Lifecycle with Rebuilt Equipment -- 5.3.6 Managing Used or Refurbished Equipment -- 5.3.7 Mothballing and Re-commissioning of Aged Assets -- 5.3.8 Partial Upgrades to Older Facilities and Equipment -- 5.4 Predicting Asset Service Life -- 5.4.1 Mean Life and Age -- 5.4.2 Assessing End-of-Life Failure Probability -- 5.4.3 Aging Process and Maintenance -- 5.5 Infrastructure Specific Topics -- 6 Inspection and Maintenance Practices for Managing Life Cycle -- 6.1 Inspection and Maintenance Goals -- 6.1.1 Vision -- 6.1.2 Inspection and Maintenance Commitment for Expected Lifecycle of Equipment.

6.1.3 Implementation of Formal Comprehensive Inspection, Testing and Preventive Maintenance Program -- 6.1.4 Need Justifiable Inspection and Maintenance Practices -- 6.1.5 Managing Aging Asset Strategies -- 6.2 Inspection and Maintenance Program Elements -- 6.2.1 Maintenance Program -- 6.2.2 Inspection Program -- 6.3 Inspection and Maintenance Program Resources -- 6.3.1 Human Resources -- 6.4 Addressing Infrastructure Deficiencies -- 6.4.1 Inspection Follow-up -- 7 Specific Aging Asset Integrity Management Practices -- 7.1 Structural Assets -- 7.1.1 Structure Foundations -- 7.1.2 Support Structures -- 7.1.3 Piping Systems, Pipe Racks and Overpass Information -- 7.1.4 Buildings -- 7.1.5 Inspection and Maintenance RAGAGEPs -- 7.2 Electrical Distribution and Controls -- 7.2.1 Electrical System -- 7.2.2 Control System -- 7.3 Earthworks: Roads, Impoundments, and Railways -- 7.3.1 Roads -- 7.3.2 Earthworks Infrastructure: Trenches, Dikes and Storage Ponds -- 7.3.3 Railways and Spurs -- 7.4 Marine Facilities: Terminals and Jetties -- 7.4.1 Marine Facilities Information -- 7.4.2 Marine Facility Inspection -- 7.4.3 Marine Facilities Aging Warning Signs -- 7.5 Underground Utility Systems -- 7.5.1 Electric Cables -- 7.5.2 Utility Underground Piping: Fuel Gas, Cooling Water, Fire Water, Drains and Sewers -- 8 Decommissioning, Dismantlement and Removal of Redundant Equipment -- 8.1 Introduction -- 8.2 Equipment Hazards -- 8.2.1 Unknown or Undocumented Condition -- 8.2.2 Dismantling Residual Chemical Hazards -- 8.2.3 Custody After Removal -- 8.3 Final Decommissioning Practices -- 8.3.1 Cleaning -- 8.3.2 Retaining Spare Equipment and Parts -- 8.3.3 Disposal of Chemicals -- 8.4 Dismantling and Disposal -- 8.4.1 Degassing -- 8.4.2 Inerting -- 8.4.3 Removal from Operating Facilities -- 8.4.4 Site Cleanup -- 8.4.5 Scrap Value -- 9 Onward and Beyond -- Acronyms.