Facility Integrity Management

Facility Integrity Management: Effective Principles and Practices for the Oil, Gas and Petrochemical Industries presents the information needed to completely understand common failures in the facility integrity management process. By understanding this more comprehensive approach, companies will be able to better identify shortcomings within their respective system that they did not realize existed. To introduce this method, the book provides managers and engineers with a model that ensures major process incidents are avoided, aging facilities are kept in a safe and reliable state and are operating at maximum levels, and any gaps within the integrity management system are identified and addressed, such as the all too common fragmented reliability programs.

The book approaches oil and gas facility management from a universal perspective, effectively charting out existing oil and gas facilities and their associated work processes, including maintenance, operations, and reliability, and then reconstructs them in order to optimize the way integrity is managed, creating a synergy across the various elements.

Easy to read, packed with practical applications applied to real process plant scenarios such as key concepts, process flow charts, handy checklists, real-world case studies and a dictionary, provides a high quality guide for a breakdown free facility, maximizing productivity and return to shareholders.

• Helps readers gain a practical and industry specific approach to facility integrity management supported with real-world case studies from oil, gas, and petrochemical facility locations
• Presents a facility integrity excellence model, a holistic approach for oil and gas companies to drive towards integrity assurance unit monitoring, creating a failure-free environment
• Identifies and addresses failure of facility processes and equipment before the onset of performance degradation, keeping equipment maintenance costs low and reliability high

Maintenance Facility Managers, Maintenance Supervisors, Plant Engineers, Operation Engineers, Petrochemical Managers, Safety Engineers and Managers, Reliability Engineers, Safety Engineers and Directors, Plant Inspection Engineers, Design Engineers, and Graduate level petroleum and safety engineers

Chapter 1: Introduction

• Abstract
• 1.1. Introduction – Facility Integrity Management
• 1.2. Changing Industrial Landscape
• 1.3. The Role of Facility Integrity
• 1.4. Facility Integrity Management Systems
• 1.5. Introduction to Facility Integrity Excellence Model
• 1.6. Design Considerations for This Book
• 1.7. Chapter-by-Chapter Synopsis

Chapter 2: Facility Integrity Excellence Model

• Abstract
• 2.1. Development of the Facility Integrity Excellence Model
• 2.2. Process Modeling
• 2.3. The Shewhart Cycle
• 2.4. Best Practices
• 2.5. Common Language
• 2.6. The Importance of Integrity Management
• 2.7. The Road to Facility Integrity Excellence
• 2.8. Facility Integrity Excellence Model Workflow

Chapter 3: Risk-Centered Culture

• Abstract
• 3.1. Introduction
• 3.2. Risk
• 3.3. Case Study – The Silo Company
• 3.4. Moving Towards an Integrated Approach
• 3.5. More on Risk-centered Culture
• 3.6. Changing an Organization’s Culture

Chapter 4: Facility Integrity and Reliability

• Abstract
• 4.1. Introduction
• 4.2. The Facility Integrity and Reliability Function
• 4.3. Reactive Approach to Facility Integrity Management
• 4.4. Moving from a Reactive to a Proactive Mindset
• 4.5. Risk-based Methods
• 4.6. Reliability
• 4.7. Inspection
• 4.8. Relative Equipment Criticality
• 4.9. Application of Criticality
• 4.10. Root Cause Analysis

Chapter 5: Maintenance Management

• Abstract
• 5.1. Introduction
• 5.2. Evolution of Maintenance Methods and Systems
• 5.3. Common Failures in Facility Maintenance Management
• 5.4. Maintenance Management Concepts
• 5.5. Equipment Maintenance and Operating Plan
• 5.6. Maintenance Workflow
• 5.7. Maintenance Strategy
• 5.8. The Right Mix

Chapter 6: Operations

• Abstract
• 6.1. Introduction
• 6.2. Facility Start-Up
• 6.3. Normal Operations
• 6.4. Abnormal Operation
• 6.5. Operating Envelopes
• 6.6. Equipment Maintenance and Operating Plan
• 6.7. Facility Monitoring Principles
• 6.8. Management of Facility Variances Workflow

Chapter 7: Integrity Supporting Processes

• Abstract
• 7.1. Introduction
• 7.2. Management of Change
• 7.3. Quality Assurance
• 7.4. Incident Reporting
• 7.5. Management of Knowledge
• 7.6. Management Review

Chapter 8: The Facility Integrity Organization

• Abstract
• 8.1. Introduction
• 8.2. Competence
• 8.3. The Integrity Organization

Chapter 9: Continuous Improvement

• Abstract
• 9.1. Introduction
• 9.2. Performance Measurement Overview
• 9.3. Integrity Performance Scorecard
• 9.4. Integrity Performance Sustainability

Chapter 10: Implementation

• Abstract
• 10.1. Introduction
• 10.2. Challenges in Change
• 10.3. An Effective Model for the Implementation of Change
• 10.4. Tracking the Change

Chapter 11: Facility Integrity Strategy

• Abstract
• 11.1. Introduction
• 11.2. The Hierarchy of Integrity Management
• 11.3. Facility Integrity Strategy Workflow