MANAGING

AGEING
PLANT
 Managing
Ageing
Plant
03 LCCA Biaya Siklus Umur
(Life Cycle Cost, LCC)
 Definition of Ageing Plant
Ageing is not about how old your equipment is; it is about its condition, and how
that is changing over time. Ageing is the effect whereby a component suffers some
form of material deterioration and damage (usually, but not necessarily, associated
with time in service) with an increasing likelihood of failure over the lifetime.
Ageing equipment is equipment for which there is evidence or likelihood of
significant deterioration and damage taking place since new, or for which there is
insufficient information and knowledge available to know the extent to which this
possibility exists.
The significance of deterioration and damage relates to the potential effect on the
equipment’s functionality, availability, reliability and safety. Just because an item of
equipment is old does not necessarily mean that it is significantly deteriorating and
damaged. All types of equipment can be susceptible to ageing mechanisms.”
www.pln.co.id |
 Ageing Asset Types
It is important to recognise that many systems and features which may be subject to
ageing, can contribute to the health, safety and environmental performance of plant,
or could compromise the performance were they to fail or collapse. A broad view is
therefore required when assessing the potential impact of ageing at a given
installation. The various asset types can be segregated into four basic categories:
• Primary containment systems
• Control & Mitigation Measures, i.e. Safeguards
• EC&I systems
• Structures
EC&I systems can be considered as a type of safeguard. However, given the different
nature and relative importance of the functions performed by this type of
equipment, it is considered desirable to highlight this category specifically.

www.pln.co.id |
 Ageing Asset Types
Table 1 : Physical Assets Considered Relevant to Ageing
Asset Type Examples
Primary Static Elements – vessels, pipework and fittings, whether at significant pressure or
Containment not, e.g. pressure vessels, columns, heat exchangers, storage tanks, open top tanks,
Systems pipework, and pipework fittings such as valves, strainers, flanges, ejectors, etc.
(Process and Rotating / Motive Elements, e.g. pumps, compressors, turbines, agitators, fans, solids
Utilities) handling equipment, etc

Control & Process Safeguard Systems, e.g.

Mitigation · Mechanical pressure protective systems – pressure/vacuum relief valves, bursting
Measures discs, vents and flares
· Mechanical overfilling protective systems - overflows, emergency dump systems
· Ignition source control equipment, eg earthing, equipment enclosures, etc
· Inerting systems (e.g. nitrogen blanketing and purging)
· Trace heating, cooling or other thermal insulation systems for process insulation
or operator protection

www.pln.co.id |
 Ageing Asset Types
Asset Type Examples
Control & Secondary or Tertiary Containment Systems, e.g.
Mitigation · Double skin vessels and pipes
Measures · Bunds
· Paved areas, kerbing, gulleys, sumps, etc
· Under soil/ underground non-permeable membranes and land drains
· Drainage systems
· Effluent treatment systems, interceptors, penstock valves for outfall isolation, etc
· Emergency holding tanks and lagoons, etc
Control and Mitigation Systems, e.g.
· Action fire protection and firewater systems, including fusible loops or plugs, fire
pumps, fire water lagoons or storage tanks, ring mains, hydrants, monitors, spray
and deluge systems, etc
· Passive fire protection systems
· Blast protection, relief and suppression systems

www.pln.co.id |
 Ageing Asset Types
Asset Type Examples
Control & · Inert gas fire suppression systems (e.g. CO2)
Mitigation · Impact protection systems e.g. crash barriers, dropped object protection, shielding
Measures · Gas knockdown or inerting systems
· HVAC systems to prevent smoke or gas ingress or protect people or key safety
critical equipment
· Communication systems - telephones, radios, PA systems
· Emergency lighting
· Spill kits, and environmental spill / release clean up or control equipment and
systems
· Portable flammable gas and toxic gas monitors etc
· PPE for use in an emergency - BA sets, gloves, chemical suits, face masks, etc
· Rescue equipment
· Emergency showers and eye wash stations
· Portable fire extinguishers and manual fire fighting equipment

www.pln.co.id |
 Ageing Asset Types

Asset Type Examples

Control & External Hazard/Environmental Safeguards, e.g.
Mitigation · Flood protection arrangements
Measures · Lightning protection
· Trees or other natural features/ecosystems that could impact plant/pipelines if
they collapsed or caused root damage or burrowing, or block outfalls or overflows
· Areas prone to subsidence, rock fall or land slip, etc
EC&I Systems EC&I - safety critical process safeguarding systems (trips, alarms, process ESD, etc)
EC&I - safety critical leak detection and response systems (fire and gas leak / area
detection, emergency shutdown systems) Integrity and availability of key
services such as power supply, UPS, emergency back up generators, battery
units, etc
CCTV Monitoring of plant areas and escape routes, etc

www.pln.co.id |
 Ageing Asset Types
Asset Type Examples
Structures Supporting structures, civils features and foundations for:
· Primary containment
· Secondary and tertiary containment, including bunds, kerbs, drains, effluent and storm/
fire-water lagoons and basins
· Providing impact protection, e.g. protection from vehicle collision, blast, lifting
operations, gas cylinders, etc
· Safe places of work, e.g. controls rooms, offices, workshops, emergency shelters
· Access and escape routes, e.g. roadways, ladders, stairs, gantries, walkways, etc
· Safety critical services and utilities, e.g. power distribution, equipment and battery
rooms, etc
Safety critical EC&I equipment, weatherproofing, ingress protection, etc
Structures and civils features that could impact major hazard plant, pipelines or equipment
(including EC&I and safeguarding equipment, cabling, etc) were they to collapse / fail, or
which could disperse spilt material if they were to leak/ fail, e.g. flood defences, chimneys,
communication towers, canal or reservoir embankment, sea
defences, buildings, walls, flares/ stacks, tall lighting towers, earth embankments, retaining
walls, culverts, bridges, tunnels, underground caverns, etc

www.pln.co.id |
Prevalence and Impact of Ageing on Major Hazard Plant

Dari perspektif health, safety and environmental, perlu untuk mampu

mengidentifikasi site dan instalasi dimana ageing (penuaan) mungkin ada
dengan kenaikan risiko yang besar.
Hal init tergantung pada beberapa faktor, termasuk:
· The inherent hazards and risks of the installation
· The propensity of the installation to ageing related deterioration or
damage
· The likely types of ageing mechanisms and where and how these could
present themselves
· The extent to which ageing is being effectively managed

www.pln.co.id |
Ageing Mechanisms and their Management

www.pln.co.id |
 Ageing Mechanisms and Material Type

their Management

Process Fluid

High Likelihood of Ageing Degradation

Medium Likelihood of Ageing Degradation
Low Likelihood of Ageing Degradation

www.pln.co.id |
Mekanisma ageing, dimana mungkin terjadi, dan cara mengenali dan mengelolanya.

Korosi
Korosi dapat diartikan sebagai degradasi fisikal suatu material karena reaksi kimia
yangterjasdi pada permukaan ketika terpapar ke lingkungan memungkinkan reaksi.
Wet (Aqueous) Corrosion & Dry (Hot) Corrosion
Mekanisma korosi
General Corrosion
Localised Corrosion
galvanic corrosion
Pitting corrosion
Crevice corrosion
Galvanic corrosion

www.pln.co.id |
Specific Types of Common Corrosion
Carbon Dioxide (Sweet) Corrosion
Hydrogen Sulphide (Sour) Corrosion
Atmospheric Corrosion
Microbial Corrosion :
· Presence of bacterial life in the system.
· Source of Sulphate.
· Source of Carbon.
· Source of water.
· Anaerobic conditions.
· Close to Neutral pH.
· Suitable temperature and pressure for bacterial life to be sustained.

www.pln.co.id |
Signs and Symptoms
Corrosion is perhaps one of the more obvious signs of plant ageing because of
visible signs of corrosion product, either external or internally within equipment.
The nature of many materials, especially carbon and low alloy steels, is to react with
the environment by a corrosion process to attain a more stable condition, e.g.
metallic iron “wants” to become iron ore again.
Many equipment items take account of this in the design process e.g. corrosion
allowance so it is important to note that the presence of corrosion products, i.e. rust,
does not indicate that equipment is not fit for its service. Rust is merely a sign that
the equipment is ageing. The rate of this ageing process and its importance in risk
terms are parameters the plant operator should be concerned with.

www.pln.co.id |
Susceptibility (kerentanan/kelemahan)
All metallic materials are susceptible to corrosion and/or corrosion cracking.
Materials termed “corrosion resistant alloys” or CRAs are less susceptible but not
immune. This class of materials are protected by a corrosion process that forms a
thin layer of metal oxide at the surface. Should the layer be damaged in an
environment that does not support re-oxidation, then the material can become
susceptible to corrosive attack.

Bacterial Degradation

www.pln.co.id |
 CO2 Corrosion

SourCorrosion and Cracking

Erosion Corrosion

www.pln.co.id |
Management Options
Corrosion can be prevented or monitored and controlled. Prevention methods include
coatings and/or cathodic protection (often termed “CP”). CP can be achieved either by
the use of impressed currents or by connection of sacrificial anodes typically made from
zinc or aluminium blocks. If coatings are used there should be evidence of coatings
inspection and if CP is employed evidence of maintenance and monitoring of CP
effectiveness should be available.
For monitoring and control, management of corrosion is achieved through the following
processes:
· Identification
· Detection
· Quantification
· Assessment
www.pln.co.id |
www.pln.co.id |
Identification usually involves a risk assessment, e.g. RBI plan or may take the form
of asset registers arranged to identify those equipment items that are expected to
corrode in one way or another.
Detection is the application of a suitable inspection technique, often visual, that can
locate the corrosion.
Quantification is achieved by measuring the remaining thickness of material
available to contribute to the overall structural integrity of the equipment. In some
instances, engineering judgement is applied but this should be documented to a
sufficient extent that reasonable next inspection intervals can be deduced.
Whenever corrosion is detected an assessment, should be made of its implications
for equipment integrity. This assessment should inform any actions that are to be
taken in the future including inspections and any repairs/modifications that may be
made
www.pln.co.id |
Stress Corrosion Cracking
Mechanisms: - Chloride Stress Corrosion Cracking
- Hydrogen Induced Cracking (HIC)
- Corrosion Fatigue
Signs and Symptoms:
SCC is notoriously difficult to detect without the aid of NDT. However, there are tell-
tale
signs that indicate that SCC might be present in certain cases. For instance, it is well
known that pitting corrosion at welds in corrosion resistance alloys is often (though
not always) a precursor to SCC since cracks often begin at the bottom of pits.
Additionally and in the same alloy group, the surface may exhibit rusty staining with
little or no apparent source. This staining is corrosion product originating from
within a tight stress corrosion crack.
www.pln.co.id |
Stress Corrosion Cracking

www.pln.co.id |
Susceptibility Guide to Stress Corrosion Cracking

www.pln.co.id |
www.pln.co.id |
Management Options
SCC requires the combination of a susceptible material, a tensile stress
and an aggressive environment. SCC should be prevented at the design
stage by the appropriate selection of materials and control of the stress
levels. The unpredictable nature of SCC renders it extremely difficult to
monitor and control. If SCC is found it should be repaired or measures
taken to fully mitigate the potential consequences of any failure.

www.pln.co.id |
Erosion
Mechanisms
Erosion is the removal of the surface of a material by abrasion. Hard particles impact the
surface causing surface wear resulting in loss of material. Erosion is fundamentally
different to corrosion because it is not an electrochemical process. It depends mainly on
the difference in hardess between the material and the impacting particles and the
velocity and impact angle.
Erosion if often found in systems where solids are transported, e.g. systems containing
sand, solid products or slurrysE. rosion can be caused by the impact of liquid particles,
e.g. in condensing steam systems.
Signs and Symptoms
Prior to failure the most important sign of erosion is the loss of material thickness at
certain points in a system or structure.

www.pln.co.id |
Susceptibility
All materials are susceptible to erosion when impacted by harder particles. Particular
susceptibility occurs at positions where there are changes in flow direction and/or
velocity, for example at piping bends or choke valves.
Management Options
Management options for erosion are the same as for corrosion. Erosion can be
prevented or monitored and controlled in the same way as corrosion and the same
assessment methods apply.

Erosion of a Pipe Bend

www.pln.co.id |
Corrosion Under Insulation (CUI)
The presence of external insulation coverings on pipelines and vessels can lead to
corrosion which is much more severe than would be expected if the equipment was
uncoated. There are several reasons for this to happen:
· The insulation creates a creviced area at the surface of the metal which can retain water.
· The insulation itself may absorb or wick water.
· The insulation material may contain contaminates which increase the corrosion rate.
· The insulation hides from view almost all visual evidence of corrosion occurring underneath.

There are two main sources of water under insulation:

· Condensation.
· External sources such as rain, cooling tower discharge, condensate dripping from
cold equipment above, steam discharge, process liquid spillage, etc.

www.pln.co.id |
Corrosion Under Insulation

www.pln.co.id |
Inspection of insulated equipment
Inspection is difficult as the metal surface is covered by insulation. Complete removal of
the insulation would be needed to allow for a thorough visual inspection of the metal
surfaces for CUI. Visual inspections should begin by identifying areas where damage and
breaks to the weatherproofing potentially allowing water ingress are visible; swollen or
misshapen insulation can indicate the presence of rust built up below the insulation.
If no areas of damaged weatherproofing are visible then inspections should concentrate
on the following areas:
· Surfaces exposed to frequent hot to cold cycles.
· Cold temperature equipment with parts which project through the insulation.
· Interfaces between hot and cold equipment.
· Horizontal pipe work, especially where there are joints and branches extending from
the base.
www.pln.co.id |
Inspection Techniques
The standard inspection technique is to remove small sections of the insulation at
regular intervals across the pipework to allow inspection of the condition of the
metal surface below. Appropriate techniques for inspection of pipework, once a small
spot of insulation has been removed, include:
· Visual inspection of the surface for evidence of dampness, coating defects and
surface rusting.
· Ultrasonic wall thickness measurements can be taken to asses the level of wall loss
due to general corrosion.
· For Stainless Steels where no general corrosion would be expected a visual inspec-
tion for evidence of localised areas of rust staining indicating the presence of pits
or crevice corrosion can be conducted and a technique such as Dye Penetrant used
to identify SCC cracks in the structure.
www.pln.co.id |
Some inspection techniques that allow the entire structure to be inspected are :
Flash Radiography
Guided Wave Ultrasonic
Profile Radiography
The following techniques are applicable to assessing general corrosion only;
· Pulsed Eddy Current
· Digital Radiography
· Infrared Thermography
· Neutron Backscatter
Inspection Techniques for Pitting
External pits can be identified visually by tell tale rust stains surrounding the pitting.
Internal pits can be visually inspected in the case of large vessels where entry is practical.
Pit Monitoring: Electrochemical noise measurements can be used to monitor pitting formation
in real time
www.pln.co.id |
Machines & Rotating Equipment
Loss of containment from age related deterioration of machinery and/or rotating
equipment can occur in the same way as for static equipment. The range of mechanisms
that can cause such integrity failures are essentially the same as those for static
equipment but the dynamic nature of machines can exacerbate the rate of deterioration
in some instances.
· Build up of solids on a fan impeller can cause fatigue failure and ejection of parts.
· Corrosion or fouling of turbine over-speed protection devices.
· Valve seizure (particularly important for pressure relief valves).
· Fouling of an oil cooler which causes lubrication failure that in turn causes bearing failure,
resulting in shaft failure and ultimately, breach of containment.
· Blockage of heat exchanger tubing/pipes.
· Corrosion or fouling of pumps or fan impellers can reduce throughput and adversely affect the
performance of associated equipment, e.g. a cooling system.
· Vibration of rotating equipment due to out of balance.
www.pln.co.id |
Fired Heating Equipment
Fired heating equipment is subject to ageing both on the fire-side and the process side.
Normal ageing processes discussed above apply, e.g. corrosion, stress corrosion cracking
etc, but are added to with specific ageing mechanisms related to the high temperatures
on the fire-side, e.g. high temperature oxidation and creep. In addition, significant
thermal cycling can give rise to fatigue over a period of time and metallurgical changes
can occur because of prolonged service at high temperatures.
More detail on potential damage mechanisms and methods of inspection that should be
used can be found in API Recommended Practice 573 on “Inspection of Fired Boilers and
Heaters”

www.pln.co.id |
Non-Metallic Materials
Composites do not corrode, but can be subject to a number of degradation mechanisms in-
service including physical ageing, mechanical ageing and chemical ageing.
The consequence of these can be a reduction of 20 - 40% or greater in the strength characteristics
of the polymer during the lifetime of the component and introduction of damage including matrix
cracking and delaminations. This is handled in design codes by use of regression curves based on
short term and longer term (typically 1000h) tests to determine the qualification pressure for the
component and the allowed operating pressure over the design life.
There is concern about whether such methods of life assessment are sufficiently robust, given the
increasing diversity of applications in which composites are applied. In contrast to steel vessels or
pipework where non-destructive methods such as ultrasonics, electromagnetics and radiography
are widely applied, very little inspection other than visual inspection or pressure testing is
currently undertaken on composite components in the chemical, process and petrochemical
industries.
www.pln.co.id |
Concrete Support Structures
Concrete, especially reinforced concrete, is as susceptible to ageing effects as any other
material. Common Causes of Defects in Concrete Structures:

www.pln.co.id |
Glass Reinforced Plastic (GRP)/Glass Reinforced Epoxy (GRE) Tanks
Glass-reinforced Plastic/Epoxy is a composite material which is commonly used for tanks
and pipes in areas that are not normally exposed to high temperatures or pressures,
often this material is used for storing and transporting water. GRP/E is manufactured by
forming tiny glass fibres into an overlapping mesh within a mould with a thermosetting
plastic or epoxy resin placed between the layers.
Buried Pipes
Metallic pipes and tanks buried below ground would, if left unprotected, undergo
external corrosion depending on the material composition and the local environmental
conditions. In order to prevent corrosion and subsequent failure of the pipe or tank, the
exterior surfaces of buried metallic structures are typically protected by both a coating
and a cathodic protection system.

www.pln.co.id |
Management of Ageing
Plant ageing should be managed as part of a well structured Health, Safety and
Environment Management Systems (HSEMS). In many cases the term “ageing” may not
be mentioned explicitly but management of ageing issues should be catered for in the
management of system integrity and functionality and covering all asset types.
· Maintenance Management Systems
· Asset Management and Integrity Systems
· Audit and Inspection regimes
· Risk Assessment Management processes
· Management of Change procedures
· Permit to Work
· Responsibilities and Communications
· Training and Competence development
www.pln.co.id |
Every business is different and therefore the number and focus on KPIs will differ. There is
no right system for all and it is a requirement of the management team to identify the
key process indicators they wish to monitor in relation to ageing plant issues and the
control of major hazards.
The following are just some of the key indicators to be considered.
Leading Indicators
· Number of planned inspection,
· Number and frequency of audits
· Planned replacement schedules for plant and equipment
· Number of Emergency Response exercises planned.
· Planned number of tests done on safety critical equipment.
· Training plans for identified staff and staff numbers attending.
· Planned procedure reviews
www.pln.co.id |
Lagging indicators
· Number of major failures of plant and equipment.
· Number of uncontrolled releases of product.
· Number of reworks to maintenance activities
· Number of outstanding audit/Inspection action items.
· Number of alarm/instrument failures during testing
· Number of incidents when working under a Permit to Work system
· Number of incidents due to Human Error.

www.pln.co.id |
The pipework was inspected for corrosion only and there were no proactive surveys for dead
legs/redundant drains etc.
The key Risk Control Systems missing from this operation would be as follows.
· Management of Change procedures (Not recognising the effects of change when the branch
was made redundant)
· Asset Integrity Management System (Weak assessment approach that did not include dead
legs/redundant drains etc).
· Risk Assessment/Management processes. (Not identifying the risks of leaving unsupported
redundant pipework tied to a live system)
· Audit and Inspection Regimes.(Not identifying the potential for failure of pipelines due to
vibration. Poor inspection procedures).
· Procedures (Weak procedures that did not identify and act on a trend of an increasing number
of vibration related incidents over a period of two years prior to the incident)
· Training and Competence (Staff did not recognise the potential for failure of the branch during
the continuing maintenance and operational activities of the plant).
www.pln.co.id |
Safety Management and
Risk Control Systems in
relation to Ageing Plant

www.pln.co.id |
Safety Management
and Risk Control
Systems in relation
to Ageing Plant

www.pln.co.id |
Safety Management
and Risk Control
Systems in relation
to Ageing Plant

www.pln.co.id |
Safety Management
and Risk Control
Systems in relation
to Ageing Plant

www.pln.co.id |
EC&I Specific Guidance
To provide high level guidance regarding technical and managerial issues surrounding ageing
Electrical, Control and Instrumentation (E/C&I) systems and equipment.
Examples of such systems and equipment include:- relays, switchgear, electric motors, starters,
level sensors, pressure sensors, transmitters, PLCs, DCS, SCADA, valves, pumps, etc.
In safety systems, these systems and equipment are employed to provide emergency shutdown
systems, trips, alarms etc, which either separately or in combination with other systems ensure
safety in process plant, e.g. overfill protection systems for bulk storage tanks.
Any electrical, control or instrumentation system is potentially within scope if either
(a) its purpose is to ensure that the plant or equipment stays within safe operating limits,
(b) its failure could cause a dangerous situation.

www.pln.co.id |
In determining how well E/C&I ageing plant issues are being managed there are certain
key themes, as follows:
1. Is the E/C&I equipment “ageing”?
2. Is there an understanding of the safety significance of the E/C&I equipment?
3. Are there plans for the likely replacement of at least some of the E/C&I equipment
during the lifetime of the whole plant? Is there an awareness of the technical and
resource issues?
4. Are there adequate arrangements for Maintenance and Procurement of modern E/C&I
equipment?
5. Are there adequate arrangements for Management of Change (MoC)?

www.pln.co.id |
C&I Equipment Lifecycles
Digital (or software–based) equipment shows a tendency to have significantly shorter
lifecycles. For planning purposes, the lifetime of a DCS can be taken as 15 to 20 years.
However in some instances the lifetime may be as short as 10 years, while with care and
effort some DCS systems can be kept operational for longer periods.
DCS equipment is not normally classified as safety-critical, but there may be ageing
related unreliability of the DCS which will increase the demand rates on the safety critical
systems.
E/C&I equipment life can be extended if good support arrangements are in place either
from the Original Equipment Manufacturer (OEM) or a specialist contractor.

www.pln.co.id |
C&I Equipment Lifecycles
However, in general, the following principles apply:
· C&I obsolescence is usually ultimately driven by spares availability.
· Older C&I equipment will often be analogue.
· Almost all new equipment is digital or software-based.
· Demonstrating the safety of new digital equipment requires significant effort but in
return can provide significant safety advantages

Having the capability to assure the specification and safety performance of new digital
equipment is therefore a key factor in managing the obsolescence of older C&I
equipment.

www.pln.co.id |
Cable Ageing
Cable ageing is dependent upon the type of cable (e.g. whether or not it is armoured),
the type of insulation (insulation degrade more rapidly when exposed to sunlight),
the potential for mechanical or thermal damage, and humidity. Well-specified cabling
can survive for twenty years or more outdoors and for thirty years or more indoors.
One source suggests 60 years as the accepted economic life for cables. This
benchmark value is of course dependent on many factors, such as environmental
factors and physical damage. Appropriate reviews should be carried out periodically.
Significance of E/C&I Equipment Lifetimes
The significance of the above notional values for equipment lifetimes is that, whereas
HV equipment may (with proper maintenance) last through the entire life of a typical
plant (say 30 to 40 years), it is unlikely that the same can be said for C&I equipment.
Hence operators should expect to have to carry out at least one mid-life refit of C&I
systems.
www.pln.co.id |
Issues related to Ageing E/C&I Equipment in incidents
The Ageing Plant Phase report includes an account of a data review to identify where
ageing was a significant factor in major loss of containment accidents. With regard to
E/C&I the following conclusion were drawn;
· E/C&I issues are a significant factor in around 10% of major accidents in the
MARS European Major Accident database.
· The biggest single factor in all E/C&I failures is associated with Level Detection,
often resulting in vessel overfill and loss of containment.
· Other significant causes of E/C&I failure include Loss of Site Power,
Lightning/Earthing and Software failures, including examples of issues caused
during upgrading to modern DCS control systems.

www.pln.co.id |
The review concluded that there is a need, on all high-hazard plants, for very firm
links between:
(i) the Safety Report (identifying the Safety Critical Elements (SCEs)) and
(ii) the Maintenance, Inspection and Test (MIT) schedule (taking each and every
SCE and going right down to individual instruments, logic elements and output
devices, also addressing potential initiating events like loss of supplies and
lightning strike, and defining specific test requirements and frequencies).

The MIT schedule, based on the Safety Report, needs to be matched with KPIs
measuring the backlog of safety-related maintenance, to make sure that management
can see that the appropriate MIT work is being completed.

www.pln.co.id |
E/C&I Maintenance Management
1. Maintenance Planning
a. Is E/C&I equipment classified according to its safety function?
b. Are suitable performance standards established?
c. Are there Maintenance, Inspection and Testing (MIT) plans in place?
d. Is the MIT backlog monitored?
e. Are there suitable robust arrangements for the control and management of overrides?
2. Procurement - Spares and Support Issues
a. Spares availability and storage
b. Contractual arrangements
c. Change control
d. Contingency planning and related QA issues
3. KPIs for Management of C&I Ageing – lagging and leading indicators
4. Plant History
a. Are equipment failure data records kept?
b. Is there learning from others’ failure?
5. Specific Ageing and Failure Mechanisms
www.pln.co.id |
E/C&I Maintenance Management

Maintenance Planning
Good maintenance planning is absolutely key to the lifecycle management of safety-related E/C&I
equipment..
The key aspects are:
· Safety-related E/C&I equipment should have defined performance standards.
· Safety-related E/C&I equipment should have Maintenance, Inspection and Test (MIT) plans in
place.
Testing (and proof testing) should be designed to confirm that safety-related functions are being
performed properly and most importantly that there are no unrevealed failures

www.pln.co.id |
E/C&I Maintenance Management
· Test frequencies should preferably be risk-based.
· Non safety-related E/C&I systems, if they fail, may challenge safety-related equipment.
· Good practice is to have a maintenance policy document for E/C&I equipment.
· There should be clear evidence of well-planned MIT arrangements and activities, including
evidence (KPIs) that the maintenance backlog is being properly managed.
· There should be robust managerial controls over the assessment, approval, application and
removal of all overrides.

www.pln.co.id |
www.pln.co.id |
Procurement – Spares and Support Issues
So-called E/C&I ‘ageing’ or obsolescence in practice is most often determined by
spares availability. OEM contracts may expire after a given number of years, and
spares may no longer be available. However, E/C&I equipment can in some
instances, and with care and forethought, be operated safely well beyond this point.
Issues to consider include:
· Adequate spares holding, in good storage conditions.
· Long-term support contracts with the OEM.
· Specialist contractors for some component repairs.
· Awareness of the risk of lack of change control over time in the supply of
spares from the OEM – especially for digital components.
· QA issues around buying second-hand components or potentially faked
components.
www.pln.co.id |
Plant History and Other Experience
It is important to identify and record the performance of E/C&I equipment including any in
service faults or failures and problems discovered during testing and inspection. Some
form of accessible record of plant component failures is highly desirable. Such a record
achieves, inter alia, the following:
· It enables the Maintenance Department to identify where re-working is needed and
where repeat failures occur, thus enabling smarter solutions to plant problems and
feedback to suppliers to improve or change designs
· It improves awareness and accuracy of component reliability data and failure modes.
· It enables Technical or Engineering Departments to identify those components which
have a significant adverse contribution to plant availability and safety.
· If relevant, it enables more accurate Quantified Risk Assessments of the plant.
Organisation should also have access to cross-industry sources of information which
improve awareness, and enable learning from, incidents and accidents which have
occurred elsewhere

www.pln.co.id |
KPIs for Management of E/C&I Ageing
Extensive advice on the use and development of process safety KPIs is available
elsewhere – see for example:
· HSE, Developing Process Safety Indicators, HSG 254 [13]
· Process safety KPI downloads available from www.aiche.org/ccps/metrics
Both leading and lagging indicators should be used as KPIs. Lagging indicators
measure outcome, whereas leading indicators measure processes or inputs that are
needed to deliver the desired safety outcome. In general, lagging indicators are
easier to measure and more reliable, but they only show what has already
happened, whereas good leading indicators should forewarn of future difficulties.

www.pln.co.id |
KPIs for management of E/C&I ageing

www.pln.co.id |
KPIs for management of E/C&I ageing

www.pln.co.id |
 E/C&I Management of Change
Suitable arrangements and skills for Management of Change (MoC) are essential for managing
ageing E/C&I equipment.
Solutions to E/C&I refurbishment projects or upgrades using purely analogue equipment are now
extremely difficult, since new analogue equipment is becoming increasingly difficult to procure.
Hence almost all new E/C&I equipment is digital or software-based.
In the recent past, there has been a record of some E/C&I projects (and in the wider sense, major
IT projects in general) failing to achieve their objectives. Some of these failures have been due to
the very complexity that software-based solutions make possible. Other failures have been due to
the problems of safety justification of software-based systems. Hence the replacement of ageing
E/C&I equipment requires proper arrangements for MoC. Key elements of good practice for MoC,
include:
1. High-level issues about the Company MoC capability.
2. Software maintenance and configuration management.
3. Project management issues.
4. Competency management for E/C&I maintenance, testing, modification, and refurbishment.
www.pln.co.id |
 Management of Change (MoC) Capability
Management of Change (MoC) Capability
In order to be able to replace ageing analogue equipment with digital equipment there is a need to
have robust MoC arrangements in place in accordance with IEC 61508 (Functional Safety of
electrical/electronic/programmable electronic safety-related systems) or IEC 61511 (Functional
safety – Safety Instrumented systems for the process industry sector).
The main issues for MoC are:
1. Do staff have the necessary skills?
2. Does the MoC process cover the essential aspects of IEC61508/IEC 61511? These
include: a. Functional Safety Management
b. SIL requirements assessment
c. Equipment SIL rating
d. Software maintenance arrangements
e. Software configuration management
3. Learning from the past
www.pln.co.id |
Software Maintenance and Configuration Managmnt of Plant Computer Control Systems
Plant computer control systems such as DCS can be very large and complex, sometimes
with millions of lines of code. Maintenance of these systems requires care, attention,
effort and resources.
DCS should not be used for critical safety applications, but may have a role in providing
enhanced alarm and diagnostic information which can aid safety and hence it is important
to ensure that DCS work to a high level of reliability and availability, and that changes to
them are effectively managed
A particular issue with older programmable DCS systems may be the use of obsolete
computer languages. The availability of programmers for old languages can be an issue.
Many of these issues may also apply to smaller software-based systems, e.g. discrete plant
monitoring systems, some of which may be safety-related.

www.pln.co.id |
 Where to find out more
Accident statistics and analysis
· Major Accident Reporting System (MARS)
· Major Hazard Incident Data Service (MHIDAS)
· A Review of High-Cost Chemical/Petrochemical Accidents Since Flixborough 1974,
IchemE Loss Prevention Bulletin April 1998
· Loss Prevention Bulletin, various issues
· Hazardous Cargo Bulletin, various issues
· Large Property Damage Losses in the Hydrocarbon Chemical Industries – A Thirty Year
Review, 2001
· The Costs of Accidents at Work, Health and Safety Executive, 1997
· 1999 Process Safety Performance Measurement Report, API
· Report on a Study of International Pipieline Accidents, Health and Safety Executive, CRR
294/2000
www.pln.co.id |
 Where to find out more
Ageing mechanisms and their management
· API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
· API RP 574, Inspection Practices for Piping System Components
· RR 076, Machinery and Rotating Equipment Integrity Inspection Guidance Notes
· RR 253, Piping Systems Integrity, Management Review
· API Standard 1160, Managing System Integrity for Hazardous Liquid Pipelines.
· Corrosion, Shrier, Elsevier
· Fitness-for-Service and Integrity of Piping, Vessels and Tanks. ASME Code Simplified. G
Antaki
Good practice guides
· PAS 55, Asset Management, The Institute of Asset Management
· Best Practice for Risk Based Inspection as a Part of Plant Integrity Management, CRR
363/2001
www.pln.co.id |