Asset Integrity Training for a Chemical Manufacturer Case Study

The Challenge

A chemical manufacturing company determined they needed to better manage their risk reduction by improving the effectiveness of their Asset Integrity (AI) program, also known as Mechanical Integrity (MI). Although the client wanted more efficient organization and documentation of this program internally, they lacked the expertise to educate staff for an effective improvement. The client reached out to ioMosaic for training services to meet their goals.

One critical component of any Process Safety Management (PSM) system is preventing loss of containment of hazardous process materials through proper design, installation, and testing of equipment. A comprehensive strategy for handling an overwhelming amount of asset integrity data is required for such a risk management process. A PSM system must also shape personal-safety behaviors and interactions in order to embed a sustainable safety culture within an organization. Given the client's lack of prior experience or exposure to asset integrity, employees required comprehensive training on the fundamentals ranging from asset integrity principles, practices, and measurement to practical how-tos and program sustainability.

Our Approach

The client worked with the ioMosaic team to identify their biggest challenges and developed a customized course that met their needs. The client's goals were met by four days of training for key personnel focused on removing implementation barriers, increasing competencies, the quality of procedures, and the requirements for inspection and testing. The customized course included:

1. Motivation for an AI program
2. AI program design and development
3. AI program implementation
4. Performance indicators

Customized workshops and targeted case studies were developed to help increase the training’s relevance to employees’ roles, and enrich their understanding of asset integrity concepts and their importance in day-to-day activities.

Beyond a basic methodology, participants also learned about practical asset integrity and risk reduction tools, such as Failure Modes & Effects Analysis (FMEA), Risk-Based Inspection (RBI). Preventative Maintenance (PM) / Predictive Maintenance (PdM) was covered in-depth. Managing equipment information, test and inspection results, and deficiency tracking was also reviewed. They learned how a data management system with workflows, like Process Safety Enterprise^®, contributes to streamlining an AI program for long-term, cost-effective maintenance.

The involvement of many employee levels and departments meant that participants were informed not only about their own roles and duties for developing and maintaining an AI program but also gained an awareness of the roles around them to help identify responsibility gaps or overlaps. This improved understanding and increased the efficiency of the program implementation. Holding the training in-person and on-site provided group interaction and participation that may not normally occur on the shop floor. Facilitators with extensive first-hand experience shared with the client additional insight and recommendations to resolve potential gaps.

The Benefits

The success of any asset integrity program requires awareness, knowledge, and commitment from its employees about asset integrity, its significance, and how to sustain effective practices. Through training, participants gained a firm understanding of asset integrity concepts, the skill sets needed to update their AI procedures, improve their program, and how to make the program more efficient using best industry practices (RAGAGEP). Employees contributed to every aspect of their AI program as well as to the plant’s overall safety.

Learn More

Our mission is to help you protect your people, your plant, your stakeholder value and our planet. To learn more about how we can help you manage risk, call us at 1.844.ioMosaic.