Page 155 - Pipeline Risk Management Manual Ideas, Techniques, and Resources

61132 Incorrect Operations Index
open or closed as required) is not correct. A command to open a ment. These programs can be quite sophisticated in terms ofthe
valve will not execute if the pressure on either side of the valve rigor of the data analysis. Use of even rudimentary aspects of
is not in an acceptable range. Such electronic permissives are PPM provides at least some evidence to the evaluator that main-
usually software programs that may reside in on-site or tenance is playing a legitimate role in the company’s risk reduc-
remotely located computers. A computer is not a minimum tion efforts.
requirement, however, because simple solenoid switches or The evaluator may wish to judge the strength of the mainte-
wiring arrangements may perform similar functions. The eval- nance program based on the following items:
uator should assess the adequacy of such permissives to
perform the intended functions. Furthermore, they should be DI. Documentation 2 pts
regularly tested and calibrated to warrant the maximum point D2. Schedule 3 pts
scores. D3. Procedures IO pts
Highlighting of critical instruments This is merely another D1. Documentation (0-2 pts)
method of bringing attention to critical operations. By painting
a critical valve the color red or by tagging an instrument with a The evaluator should check for a formal program of retaining
special designation, the operator will perhaps pause and con- all paperwork or databases dealing with all aspects of mainte-
sider his action again. Such pauses to reconsider may well pre- nance exists. This may include a file system or a computer data-
vent serious mistakes. Points should be awarded based on how base in active use. Any serious maintenance effort will have
effective the evaluator deems the highlighting to be. associated documentation. The ideal program will constantly
adjust its maintenance practices based on accurate data collec-
tion through a formal PPM approach or at least by employing
D. Maintenance (suggested weighting: PPM concepts. Ideally, the data collected during maintenance,
15%) as well as all maintenance procedures and other documenta-
tion, will be under a document management system to ensure
Improper maintenance is a type of error that can occur at sev- version control and ready access of information.
eral levels in the operation. Lack of management attention to
maintenance, incorrect maintenance requirements or proce- DZ. Schedule (0-3 pts)
dures, and mistakes made during the actual maintenance activi-
ties are all errors that may directly or indirectly lead to a A formal schedule for routine maintenance based on operating
pipeline failure. The evaluator should again look for a sense of history, government regulations, and accepted industry prac-
professionalism, as well as a high level of understanding of tices will ideally exist. Again, this schedule will ideally reflect
maintenance requirements for the equipment being used. actual operating history and, within acceptable guidelines, be
Note that this item does not command a large share of the adjusted in response to that history through the use of formal
risk assessment points. However, many items in the overall PPM procedures or at least the underlying concepts
pipeline risk assessment are dependent on items in this section.
A valve or instrument, which due to improper maintenance will D3. Procedures (0-10 pts)
not perform its intended function, negates any risk reduction
that the device might have contributed. If the evaluator has The evaluator should verify that written procedures dealing
concerns about proper operator actions in this area, she may with repairs and routine maintenance are readily available. Not
need to adjust (downward) all maintenance-dependent vari- only should these exist, it should also be clear that they are in
ables in the overall risk evaluation. Therefore, ifthis item scores active use by the maintenance personnel. Look for checklists,
low, it should serve as a trigger to initiate a reevaluation of the revision dates, and other evidence of their use. Procedures
pipeline. should help to ensure consistency. Specialized procedures are
Routine maintenance should include procedures and sched- required to ensure that original design factors are still consid-
ules for operating valves, inspecting cathodic protection equip- ered long after the designers are gone. A prime example is
ment, testingcalibrating instrumentation and safety devices, welding, where material changes such as hardness, fracture
corrosion inspections, painting, component replacement, lubri- toughness, and corrosion resistance can be seriously affected
cation of all moving parts, engine/pump/compressor mainte- by the subsequent maintenance activities involving welding.
nance, tank testing, etc.
Maintenance must also be done in a timely fashion.
Maintenance frequency should be consistent with regulatory Incorrect operations index
requirements and industry standards as a minimum. Modem
maintenance practices often revolve around concepts ofpredic- This is the last of the failure mode indexes in the relative risk
five preventive maintenance (PPM) programs. In these pro- model (see Figure 6.1). This value is combined with the other
grams, systematic collection and analyses of data are indexes discussed in chapters 3 through 6 and then divided by
emphasized so that maintenance actions are more proactive and the leak impact factor, which is discussed in Chapter 7, to arrive
less reactive. Based on statistical analysis of past failures and at the final risk score. This final risk score is ready to be used in
the criticality of the equipment, part replacement and mainte- risk management applications as discussed in Chapter 15.
nance schedules are developed that optimize the operation- Chapters 8 through 14 discuss some specialized applications of
not wasting money on premature part replacement or risk techniques. If these are not pertinent to the systems being
unnecessary activities, but minimizing downtime of equip- evaluated, the reader can move directly to Chapter 15.