COURSE OVERVIEW:

The management of Integrity Critical Equipment (ICE) is a foundational element of process safety management and asset integrity frameworks within high-hazard industries. This course provides a comprehensive methodology for identifying those specific pieces of equipment whose failure could lead to a major accident event (MAE). By focusing on the "Safety Critical Elements" of a facility, participants will learn how to distinguish between standard maintenance items and those assets that serve as the primary barriers against catastrophic loss of containment. The program establishes a rigorous technical pathway for ensuring these barriers remain healthy and functional throughout the life of the plant.

The scope of this training involves the systematic development of Performance Standards for each identified ICE category, covering functionality, availability, reliability, and survivability. Participants will explore the technical nuances of various ICE types, including high-pressure trip systems, emergency shutdown valves, and primary pressure containment vessels. The curriculum emphasizes the shift from generic maintenance to "Assurance Tasks," which are specifically designed to verify that a barrier is capable of performing its intended safety function when called upon. This involves a deep dive into the engineering basis for setting test frequencies and pass/fail criteria.

Detailed coverage is provided on the "Assurance and Verification" process, which serves as the audit trail for regulatory compliance and internal safety cases. The course teaches participants how to develop Verification Schemes that utilize both internal and independent third-party competent persons to validate equipment health. By analyzing the "Bow-Tie" methodology, attendees will see exactly how ICE fits into the prevention and mitigation of major hazards. The program concludes with strategies for managing ICE deviations and impairments, ensuring that the facility maintains a clear understanding of its cumulative risk profile at all times.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the technical criteria for identifying Integrity Critical Equipment within a process plant.
• Utilize the Bow-Tie methodology to map ICE against specific major accident scenarios.
• Develop detailed Performance Standards (FARSI) for various classes of safety-critical assets.
• Establish measurable Key Performance Indicators (KPIs) for monitoring barrier health and effectiveness.
• Design assurance and verification tasks that specifically validate the safety function of ICE.
• Differentiate between "Maintenance" and "Assurance" in the context of asset integrity.
• Implement a structured process for managing ICE impairments and operational deviations.
• Apply international standards such as ISO 14224 and IEC 61511 to ICE management.
• Conduct a gap analysis between existing maintenance programs and ICE assurance requirements.
• Prepare comprehensive ICE reports for regulatory audits and internal safety committees.
• Coordinate with multidisciplinary teams to ensure ICE data is integrated into the CMMS.
• Lead "Verification Reviews" to confirm that performance standards are being met in the field.

TARGET AUDIENCE:

This course is designed for Asset Integrity Managers, Process Safety Engineers, Reliability Engineers, Maintenance Managers, and Technical Assurance Specialists. It is also highly valuable for Operations Supervisors and Plant Managers who are responsible for the safe operation of high-hazard facilities and require a structured approach to managing critical safety barriers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.