OPD-OM-MS-UK-PRE-ENG-

Bitumen Operating Document

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Critical Assessment

Purpose: To define a procedure that identifies the criticality of plant equipment and
systems and details the method of entering the criticality on the site
Computerised Maintenance Management System (CMMS) - Frontline.

Specific Process  OPD-OM-MS-UK-PRE-ENG-603-Safety Critical Measures And

Information Equipment
 DSEAR
 SIL- Safety Integrity Level
 SIS-Safety Instrumented System

Revision Date Author Checked By Validated By Approved By

0 27/02/18 D. McLeod G.Chau
1
2
3

Discipline: Maintenance Owner: D.McLeod

Personnel Trained and authorised Personnel only

assigned to task

Criticality This procedure is not deemed to be Safety Critical due to unidentified potential
failure of plant or equipment

PPE requirements Task Specific

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SCOPE
The methodology in this procedure shall be normally be applied to all new plant equipment
and systems to be assessed for criticality at Total Bitumen Preston

The Engineering Manager shall approve any other procedure used and ensure that it is
appropriate and addresses statutory requirements and good practice e.g. Pressure Systems
equipment, equipment which requires assessment for risk of Legionella.
.

REFERENCES
OPD-OM-MS-UK-PRE-ENG-603 SAFETY CRITICAL MEASURES AND EQUIPMENT

TOTAL STANDARD STD-LOG-11 CRITICALITY

DSEAR

RESPONSIBILITIES
The Engineering Manager shall ensure that the requirements of this procedure and the
relevant statutory requirements are complied with at all times.

DEFINITIONS

5.1 Criticality
This is the level of the SHEQ consequences of an item of equipment or a system failing in
terms of any SHEQ hazard such failure may cause, and also the impact of any lost production
and the cost of restoring plant to its original condition. The level of criticality varies in
ascending order: C1, C2, C3 with special attention given to scores of C4 and C5 in terms of
why an item is deemed critical (Safety, Environmental, Quality and Production). Criticality is
based on the Total UK Risk and Consequence Matrix CPR126 – see Appendix 1

5.2 DSEAR
DSEAR is a set of regulations concerned with protection against risks of fire, explosion arising
from dangerous substances used or present in the work place.
The ATEX rating for equipment situated within a DSEAR zone is carried out during the design
phase of the project it is part of. The DSEAR zones on site have all been identified and labelled

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and the report is available within the Explosion Protection Documentation of the HSEQ
department.

5.3 Safety Instrumented System (SIS)

A safety instrumented system covers all parts of the system that are necessary to carry out
the safety function e.g.
 Initiator of the trip – tank level switch
 Logic solver / relay – hardwired hardware (PLC or PILZ relay) or software actions the
required response / trip: stopping pumps etc…
 Final element – tank inlet pumps and valves

5.4 Independent Protective Layer (IPL)

An IPL is a device, system or action, which is capable of preventing a scenario from
proceeding to its undesired consequence independent of the initiating event or the action of
any other layer of protection associated with the scenario. For example, the tank above with
an independent “hihi” level switch could also be situated within a bund. The tank therefore
has two layers of protection: SIS & bund. It should be noted that a Layer Of Protection analysis
(LOPA) is the basis for a ‘Bowtie’ diagram

5.5 Trip
A trip is an SIS. A trip by definition is the automatic plant response to an excursion above or
below normal process parameters leaving the plant in a safe state e.g. the action of tripping
the pump and closing of the inlet valves for the loading tank reaching “hihi” and activating the
level switch.

5.6 Safety Integrity Level (SIL)

A measurement of the effectiveness of SIS, safety instrumented systems based on the
probability of tolerable incidents that can occur within a number of processing demands within
a stated period of time. SIL evaluations can rate SIS from 0 to SIL1, SIL2, SIL3 or SIL4
The SIL rating for all SIS is carried out during the design phase of the project it is part of and
must comply with IEC61511.

5.7 SIL Trip

SIL rated trips are by definition the same as a normal trip but have a lowering probability of
failure on demand with increasing severity and likelihood of the risk they control i.e. if the tank
mentioned above was used for gasoline rather than water, the SIS would require a SIL rating.

5.8 Alarm
An alarm is an unexpected occurrence that requires a timely operator action e.g. a tank alarm
reaching “hi” on the radar allowing the operator to stop the relevant pumps etc… before the
“hihi” SIS trip stops loading automatically.

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5.9 Frontline
Frontline is the Computerised Maintenance Management System (CMMS) installed at Total
Bitumen. Each item of equipment, system, plant or building entered into Frontline requiring
regular maintenance or examination has a routine Plan established with an associated
schedule that generates work requests automatically. For all unplanned works onsite, a work
request is generated through Frontline by Operations.

5.10 Functional Location

Each asset on the plant has been given a functional location number that is often used by
Production and Maintenance alike for process equipment. The functional location is displayed
by each piece of kit on the DCS screens e.g. P144, MV102, T302, TI3325, LS3385 etc….

5.11 Asset Number

Each piece of kit entered into Frontline is given an asset number regardless whether it is
process plant or not. This allows for the identification, maintenance and inspection of all kit
onsite. The asset number is always a six digit number and when known must be entered into
Frontline as a six digit number e.g. 000001, 002352 etc…

5.12 Provision and Use of Work Equipment Regulations (PUWER)

PUWER is the UK statutory regulation covering the safe use of work equipment including the
requirement to establish a suitable maintenance regime to ensure any risk from the equipment
is tolerable.

5.13 Preventive Maintenance Replacement

Operation of maintenance executed in pre-determined intervals or according to prescribed
criteria where critical items of equipment / components are replaced irrespective of their actual
condition. Preventive Maintenance Replacement is intended to reduce the probability of failing
or the degradation of the functioning of equipment.

5.14 Preventive Maintenance Systematic

An operation of preventive maintenance executed in intervals of time without preliminary
control of the state of the equipment. Where items of equipment / components are inspected
and replaced dependent upon their condition. 5

5.15 Preventive Maintenance Conditional

An operation of preventive maintenance based on a surveillance of equipment where
replacement or repair is required following observation or inspection of a defective condition.

5.16 Run to Fail (Breakdown Maintenance)

No inspection maintenance required.

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PRINCIPLES
All new plant equipment and systems shall be considered for critical assessment using the
methodology/spread sheet in this procedure.

Existing Equipment may be assessed using other agreed procedures provided this is
approved by the Engineering Manager.

All opportunities to bring existing equipment critical assessment into this procedure shall be
longer term aim and reviewed by the Engineering Manager.

Where equipment or systems are assessed as Critical, appropriate required maintenance,

inspection and operating task procedures shall be established as well as ensuring the
competency requirements for personnel involved.

It should be noted that the final results of the critical assessment are always at the discretion
of the Critical Assessment Team and that this policy serves as a guide to the assessment
procedure

PROCEDURE FOR ASSESSING CRITICALITY

All equipment entered into Frontline must be subject to a formal critical analysis as part of the
MOC project. The “Critical Assessment spread sheet” shall be used for the survey along with
the relevant P&IDs, trip procedures etc… with the results entered on the “Frontline Asset
Creation Form”. The critical assessment team shall include relevant competent personnel.

The “Critical Assessment spread sheet” itself is split up into the following sections

7.1 Asset Registration

Basic Process Description
Is the Asset new or existing? (choice of new / ex)
What is the new functional location? (type in FL tag)
If applicable, what “was” the old functional location? (type in FL tag)
Frontline (CMMS) asset number if known (e.g. 002354)
On which P&ID is the equipment displayed? (type in P&ID number)

7.2 DSEAR
Does the equipment require an ATEX / DSEAR inspection i.e. is it located in a hazardous
area? (type in y or n)

7.3 SIS
7.3.1 Is the equipment part of a Safety Instrumented System (SIS)? (type in y or n)

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7.3.2 If the equipment is part of an SIS, what is the Functional Location of the SIS initiator?
(type in FL tag)

7.4 Critical Assessment What is the likelihood of failure? (1 to 5) (Probability of Failure PF)
When estimating the banding of the functional failure probability, consideration should be
given to aspects such as:
 Operational failure history (where available)
 Generic reliability data
 Equipment redundancy
 Mode of equipment operation
 Equipment stress variations, etc.

The assessment should be a group exercise using historical data, engineering and on site
knowledge and the Site Risk and Consequence Matrix CPR 126
The following categories are assessed in terms of potential consequence of failure. The
consequence is based upon guidance derived from the risk and consequence matrix. Note
the consequence should be the most probable not the worst case.
When the correct level of consequence has been decided, the figure “1” must be placed in the
chosen column on the “Criticality Assessment Spreadsheet”.
7.5 Injury / Safety (S): impact of loss of function upon safety (1 to 5)
7.6 Environment (E): impact of loss of function upon environment (1 to 5)
7.7 Quality (Q): impact of loss of function upon quality (1 to 5)
7.8 Production Impact (P): impact of loss of function upon production (1 to 5)

7.9 Critical Summary (for Frontline)

The results from the critical assessment are automatically summarised on the “Critical
Assessment spread sheet” in section 7.9. The results are consistent with the Risk and
Consequence Matrix. The summary of the critical review is then to be used to give the
equipment under investigation the final ratings for Frontline.

Safety RA matrix
1 2 3 4 5
1 C1 C1 C2 C3 SC4
likelihood

2 C1 C2 C3 SC4 SC4
3 C2 C2 C3 SC4 SC4
4 C2 C3 C3 SC4 SC5
5 C3 C3 SC4 SC5 SC5
consequence

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The asset category “Criticality” on Frontline has a main heading and two subgroups:
7.9.1 DSEAR - if the equipment is located in a hazardous area and requires inspection. In
this field all equipment is either DSEAR or nonDSEAR.

7.9.2 Overall Criticality level (C1, C2, C3, PC4, PC5, QC4, QC5, EC4, EC5, SC4, SC5) - is
generated automatically from the summary data and prioritised to give an overall criticality
score i.e. SC5 is the highest score an item of equipment can have and overrides all other
results for Environment, Production and Quality. See priority table below.

final priority
criticality order
rating
Safety SC5 1

Safety SC4 2

Environmental EC5 3

Environmental EC4 4

Quality QC5 5

Quality QC4 6

Production PC5 7

Production PC4 8

critical score C3 9

critical score C2 10

critical score C1 11

 7.10 Service Category

The “Service Category” is used on Frontline to categorise important headings of plant
equipment:

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 Trip
 SIL Trip
 Alarm
 Pressure System Regs
 Piping
 Tanks
 HV Electrical
 Electrical
 Thermal Oil
 LEV
 Lifting Equipment
 Bund/Drain
 Structure
 N/A

Once the critical assessment is complete, the Critical Team must then choose the most
appropriate “Service Category” from the list above. For all items C3 or above, a “Service
Category” is mandatory.

7.11 Maintenance Cost Impact (CI) is the estimated cost to the business to repair and
replace equipment (assess as 1 to 5 – based on cost bands indicated)

7.12 Agreed Maintenance

The final part of the “Criticality Assessment Spreadsheet” requires the critical assessment
team to detail the required maintenance for the equipment:
7.12.1 Calibration Requirements: if the equipment requires calibration, the period of
calibration can be entered in months (enter value in “X” months)
7.12.2 Written Scheme: is the equipment to undergo a written scheme of Inspection? (type in
y or n)
7.12.3 DSEAR : automatically displayed results from the critical assessment
7.12.4 SIS: automatically displayed results from the critical assessment
7.12.5 Maintenance Regime: judgement as to the Maintenance regime required

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The Critical Team must review the level of criticality for the equipment and thus decide from
the list below which Maintenance regime/type is required (note the explanations are in the
definitions chapter of this policy):
 Preventive Maintenance Replacement
 Preventive Maintenance Systematic
 Preventive Maintenance Conditional
 Run to Fail

The Maintenance regime required remains for the Critical Team to review, though the following
list can be used as guidance:
 (C5 / C4) Preventive Maintenance Replacement / Systematic
 (C3 / C2) Preventive Maintenance Conditional
 (C2 / C1) Run to Fail

8. DOCUMENTATION
The Critical assessment Spread sheet shall be used to document the
assessment – see Appendix 2 for template and example.

9. TRAINING AND COMPETENCE

All personnel who are part of an Assessment Team shall be fully trained in this
procedure and Project Managers shall be made fully aware of the
requirements of the ` procedure.

10. AUDIT
HSEQ shall ensure that compliance with this procedure is regularly audited.

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