QC-PSM-GLN-00-0002

GUIDELINE
EQUIPMENT CRITICALITY GUIDELINE

REV. 1
15-DEC-2009
Page 1 of 13

TABLE OF CONTENTS

1.

INTRODUCTION ...................................................................................... 2

2.

SCOPE / PURPOSE ................................................................................. 2

3.

DEFINITIONS ........................................................................................... 2

4.

GUIDELINE .............................................................................................. 3

4.1.

Criticality Defined ................................................................................ 3

4.2.

Evaluation Methodology ..................................................................... 3

4.3.

Criticality Scoring ............................................................................. 11

4.4.

Criticality Application ....................................................................... 11

5.

RESPONSIBILITIES .............................................................................. 12

6.

REFERENCES ....................................................................................... 12

ATTACHMENTS ............................................................................................ 12
APPENDICES................................................................................................ 12

Rev.

Issue Date

0
1

19-Apr-2006
15-Dec-2009

Amendment Description
Initial Release
Periodic Review and General Revision

Page 1 of 13

Prepared
By:
MJK
JIK

Chkd
By:
MJK
CU

Apprd
By:
MSS
ZAK

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1.

INTRODUCTION
Equipment Criticality is a measure of equipments impact on Safety and
Environment as well as Production based on the function of equipment
and process design conditions for equipment. The use of Equipment
Criticality at Qatar Chemical is to provide additional focus on equipment
which may have a higher degree of impact should the equipment not
function properly and/or fail.

2.

SCOPE / PURPOSE
Equipment Criticality as defined in this document is applicable to process
equipment covering Electrical, Instrumentation, Rotating, and Stationary
equipment disciplines. The intent of this document is to outline the
methodology(s) used to evaluate and categorize equipment into one (1) of
three (3) levels of criticality which is synonymous with priority.
The criticality classification is used as a guide as to the extent of detail/level of
application for the following activities.

Preventive Maintenance
Spare Parts
Inspection and Testing
Condition Monitoring
Procedures/Standard Practices
Work Order Planning/Scheduling

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3.

DEFINITIONS
ESD
SIL

- Emergency Shut Down

- Safety Integrity Level

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4.

GUIDELINE

4.1.

Criticality Defined
Equipment Criticality is a measure of an equipments impact on the plant
based on Safety, Environmental, and Operational factors. The system
employed at Qatar Chemical is a three (3) level system defined as follows.
High

Equipment in a service that has the highest potential of risk

resulting in immediate emergency if a failure occurred. Such
an emergency may be safety or environmental in nature but
could also include economic impact as the result of a
complete unit or complex shutdown.

Medium

Equipment that poses a moderate risk if a failure occurred

but does not result in a immediate emergency. Such a
situation could be safety or environmental in nature.
Economic impact could include a unit shutdown, remote, but
more likely a process disruption. Economic impact would
also focus on cost impact of equipment damage as well as
plant accounting/metering and product quality.

Low

Equipment that poses a limited if not negligible risk if a failure

occurred or process media are exposed to the environment.

Equipment Criticality may be considered synonymous with Equipment

Priority. As such a number of industry standards used as reference
material as well as computer systems use different symbols, character
references to identify this priority. The following is an equivalency table
of the typical system encountered.

Criticality per
this document
High
Medium
Low

4.2.

Reference Systems
General
API
H
1
M
2
L
3

SAP
A
B
C

Evaluation Methodology
The methodology used to determine an equipments criticality is different for
the different equipment disciplines, but the areas to address are drawn from
their impact on the following.
- Safety
- Environmental
- Operational (including economic impact)

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4.2.1.

Instrument & Electrical Equipment Methodology

The methodology for I&E equipment is based primarily on a 7 x 3 matrix as
defined in Section 4.2.1.1 below. Exceptions to this matrix are defined in
subsequent Sections 4.2.1.2 through 4.2.1.3.

Safety, Environmental,
& Production Impact

4.2.1.1. I&E Criticality Matix

Potential for life threatening injuries or
fatalities
Potential for Injuries
Potential for major environmental
impact/fire
Potential for moderate environmental
impact
Effect on Product Quality
Effect on Plant Accounting
Production loss/equipment damage only

H
H

H
H

H
H

L
L
L

M
M
M

H
H
H

< $100K

$100K
>$1M
to $1M
Economic Impact

4.2.1.2.
4.2.1.3.

All instrumentation associated with an ESD interlock system that have

been assigned a SIL rating shall be considered High critical.
All electric motors shall utilize the criticality assignment of the driven
process equipment.

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4.2.2. Rotating Equipment Methodology

Equipment Criticality for Rotating Equipment is based on a series of
questions, some implied, with a point value range associated with each one.
Although the questions may have default value, the score value for the
questions may be reduced based the individual application.
This methodology uses service parameters to identify Safety and
Environmental impact as well as process\maintenance implications resulting
from failure thereby impacting the Business/Financials. The scoring system
along with exceptions in individual score value are defined as follows. See
the Rotating Equipment Criticality Scoring Form, QC-PSM-SFM-00-0005,
which may be used to assist in scoring individual equipment.
4.2.2.1.

Safety/Environmental Impact

Question/Topic
Hydrocarbon?
What is the PH?

Gas?
Toxic?
Flammable
Auto Ignitable
Product Temperature, Design (oC)

Discharge Pressure, Design

(kg/cm^2)

Safety Miscellaneous

Option
No/Yes
7
1, 2, 13, 14
3, 4, 11, 12
5, 6, 8, 9, 10
No/Yes
No/Yes
No/Yes
No/Yes
<0
0 - 37
38 121
122 175
176 232
233 287
> 287
< 3.5
3.5 7
7.1 14
14.1 21
21.1 35
> 35.1
Open for
Comment

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Range/Value
0 - 15
0
15
10
5
0 - 15
0 - 15
0 - 15
0/15
15
0
3
6
9
12
15
0
3
6
9
12
15
0 - 15

Note
1

2
3
4

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4.2.2.2.

Business Impact

Question/Topic
Process Impact?

Impact on Assoc. Processes

Lost Production?
Cost of Repair

Spare Parts Availability

Duration of Major Repair

Option
Unit Shutdown
Proc Disruption

Range/Value
< 20
< 15

No Major Impact
No/Yes
No/Yes
Negligible <$600
Limited, $600$5,000
Low, $5,001$10,000
Medium,
$10,001-$15,000
High, $15,001$20,000
Excessive, >
$20,000
Typical, <3 days
Limited, 3-5 days
Low, 6-9 days
Medium, 10-12
days
High, 13-15 days
Excessive, >15
days
Typical, <3 days
Limited, 3-5 days
Low, 6-9 days
Medium, 10-13
days
High, 14-20 days
Excessive, >20
days
No/Yes

0
0 - 15
0 - 15
0
3

Note
6

7
8

6
9
12
15
0
3
6
9
12
15
0
3
6
9
12
15

Spared
5 to -5
9
Notes:
1. Services such as oil for bearings would be Yes but the assigned point
value may be reduced to 5 as this oil is heavy and would not be
considered as dangerous as gasoline or other light hydrocarbon.
2. Just because the service may be gas does not mandate full point value.
Air for example at ambient pressure pose no apparent risk and thus may
be assigned a value of 0.
3. Gases such as Nitrogen pose the threat of asphyxiation and may be given
a point value of 5.
4. For heavy hydrocarbons such as that mentioned in Note 1, reduced points
may be warranted\applicable.
5. This general topic was provided to allow for additional risk that may be
applicable to the application such as those including Benzene, which is a
carcinogen.
6. Unit may be represented as a section such as Reactor Train 1 alone or
the Incinerator Unit. The point value is used to identify the magnitude of
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the impact such as the Polyethylene Unit shutting down as opposed to

losing a spare pump or exchanger that results in some lesser degree of
Process Disruption. Assignment of full value should also be influenced
history, direct or like unit\plant, such that unreliable equipment warrant
higher values.
7. This may be viewed as a loss to a section or entire unit such as Ethylene
but does the failure present an impact to other units such as Utilities,
Polyethylene, etc.
8. Assigned value to be no higher than that assigned in Process Impact
with the limited maximum of 15.
9. If the equipment is not spared but has no impact on plant operation then
the assigned value is 0.
10. Although the exercise is intended to quantify the criticality measure, there
is some degree of subjectivity in the process. With this in mind, process
and equipment knowledge is key such that representation should include
Production, Maintenance, and the Equipment Reliability Group at a
minimum.
4.2.2.3.

Combined Score

The min/max for the Rotating Equipment Criticality is 0/235. The scoring
system allows the possibility of -5 but any score less than 0 is simply taken as
0.

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4.2.3. Stationary Equipment Methodology

The methodology or stationary equipment, including piping, utilizes

three (3) key factors to create a systematic and consistent classification
system for the determination of Equipment Criticality. These three (3)
factors are defined as follows based on their relative weights.

4.2.3.1.

Factor

Assigned Weight

Temperature

50%

Pressure

25%

Fluid Category

25%

Total

100%

Temperature

The temperature is sub-divided into five (5) different ranges and a score
between 1 and 4 assigned to each temperature range as shown in the
following table.

Temperature Range

Score

Normalized Score

< -150 oF (-101.11oC)

50%

-150 oF to -51 oF
(-101.11oC to -46.1oC)

38%

-50 oF to -21 oF
(-46.11oC to -29.43oC)

25%

-20 oF to 800 oF
(-29.44oC to 426.68oC)

13%

> 800 oF (426.69oC)

50%

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4.2.3.2.

Pressure

The pressure is sub-divided into three (3) different pressure classes and a
score between 1 and 3 is assigned to each pressure class as shown in the
following table.

Pressure\Flange
Class

Score

Normalized Score

8%

17%

25%

125
150
250
300
600
900
1500
2500 +
4.2.3.3.

Fluid Category

The fluid category is sub-divided into six (6) different groups of services and a
score between 1 and 6 is assigned to each pressure class as shown in the
following table.

Fluid Category

Fluid
Code

Score

Normalize
d Score

Process (Hazardous &

Toxic)

P1

25%

Process (General)

P2

21%

Chemicals (Hazardous &

Corrosive)

C1

17%

Chemicals (General)

C2

13%

Utilities (HP Steam &

Condensate, BFW, etc.)

U1

8%

Utilities (General)

U2

4%

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4.2.3.4.

Combine Scoring Distribution

Using the foregoing established scoring system, the combined scores are as
shown in the following table matrix.

4
3
1
4

800 to -20 oF
> 800 oF

-21 to -50 oF

-51 to 150 oF

< -150 oF

Temp
.
Rang
e
(50%)

Pressure Class (25%)

Fluid
Categor
y (25%)

125
1

150
1

250
1

300
2

600
2

900
3

1500
3

2500
+
3

P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2

83
79
75
71
67
63
71
67
63
58
54
50
58
54
50
46
42
38
46
42
38
33
29
25
83
79
75
71
67
63

83
79
75
71
67
63
71
67
63
58
54
50
58
54
50
46
42
38
46
42
38
33
29
25
83
79
75
71
67
63

83
79
75
71
67
63
71
67
63
58
54
50
58
54
50
46
42
38
46
42
38
33
29
25
83
79
75
71
67
63

92
88
83
79
75
71
79
75
71
67
63
58
67
63
58
54
50
46
54
50
46
42
38
33
92
88
83
79
75
71

92
88
83
79
75
71
79
75
71
67
63
58
67
63
58
54
50
46
54
50
46
42
38
33
92
88
83
79
75
71

100
96
92
88
83
79
88
83
79
75
71
67
75
71
67
63
58
54
63
58
54
50
46
42
100
96
92
88
83
79

100
96
92
88
83
79
88
83
79
75
71
67
75
71
67
63
58
54
63
58
54
50
46
42
100
96
92
88
83
79

100
96
92
88
83
79
88
83
79
75
71
67
75
71
67
63
58
54
63
58
54
50
46
42
100
96
92
88
83
79

6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1

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4.3.

Criticality Scoring
Equipment Discipline

Criticality Range
Low
Medium
High

Electrical Equipment
Instrumentation

No scoring applied, criticality

assignment per Section 4.2.1.1 of this
document

Rotating Equipment
Stationary Equipment

< 14
< 40

15 to 50
40 to 65

> 51
> 65

Comment 4.3
The division between criticality ranges for Rotating Equipment is based
on the standard distribution of the data and adjusted to where breaks in
the data occur. Based on this distribution, High criticality makes up
18%, Medium 58%, and Low 22% of the process Rotating Equipment
population.
4.4.

Criticality Application

4.4.1. Electrical, Rotating, and Stationary Equipment defined as High or

Medium criticality shall have Preventive Maintenance, Inspection,
Condition Monitoring, and/or Testing activities/schedule.
Instrumentation shall have these activities defined for equipment
assessed as High critical.
Comment 4.4.1A
The specific influence of High or Medium criticality on the Preventive
Maintenance, Inspection, and/or Testing activities/schedule is at the
discretion of the department responsible for such equipment activities
but is expected to conform to Industry Best Practice.
Comment 4.4.1B
The exception to 4.4.1 above is the Stationary Equipment Condition
Monitoring system. Piping and Vessels were classified according to
API guidelines and those assigned 1, 2, or 3 were included within the
program. As part of an improvement program, equipment already
classified have been reassessed using the criticality methodology
defined in this document. Equipment not meeting the classification
requirements during the original project assessment will be reassessed
as well but as part of maintaining a program.
4.4.2. Equipment defined as Low criticality as well as Medium for
Instrumentation may have a Preventive Maintenance, Inspection,
and/or Testing activities/schedule defined but is discretionary.
Back to top

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5. RESPONSIBILITIES
5.1.
Technical Manager
5.1.1. Responsible for applying criticality determination as defined in this document.
5.1.2. Responsible for maintaining this document.
5.2.
Equipment Reliability Superintendent
5.2.1. Responsible for maintaining and applying the Stationary and Rotating
equipment criticality methodology.
5.3.
Instrument and Electrical Superintendent, Technical
5.3.1. Responsible for maintaining and applying the Instrument and Electrical
equipment criticality methodology.

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6. REFERENCES
QC-PSM-SFM-00-0005
HSE-SAF-TBL-00-0004

- Rotating Equipment Criticality Scoring Form

- Risk Ranking Matrix

Back to top

ATTACHMENTS
Back to top

APPENDICES
A

Stationary Equipment Criticality Classification Table

Back to top

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Appendix A

Stationary Equipment Criticality Classification Table

APPENDIX A Stationary Equipment Criticality Classification Table

Criticality Classification Matrix, Stationary Equipment

4
3
1
4

800 to -20 oF
> 800 oF

-21 to -50 oF

-51 to 150 oF

< -150 oF

Temp
.
Rang
e
(50%)

Fluid
Categor
y
(25%)
P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2
P1
P2
C1
C2
U1
U2

6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1

Pressure Class (25%)

125
1

150
1

250
1

300
2

600
2

900
3

1500
3

2500
+
3

H
H
H
H
H
M
H
H
M
M
M
M
M
M
M
M
M
L
M
M
L
L
L
L
H
H
H
H
H
M

H
H
H
H
H
M
H
H
M
M
M
M
M
M
M
M
M
L
M
M
L
L
L
L
H
H
H
H
H
M

H
H
H
H
H
M
H
H
M
M
M
M
M
M
M
M
M
L
M
M
L
L
L
L
H
H
H
H
H
M

H
H
H
H
H
H
H
H
H
H
M
M
M
M
M
M
M
M
M
M
M
M
L
L
H
H
H
H
H
H

H
H
H
H
H
H
H
H
H
H
M
M
M
M
M
M
M
M
M
M
M
M
L
L
H
H
H
H
H
H

H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
M
M
M
M
M
M
M
M
M
H
H
H
H
H
H

H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
M
M
M
M
M
M
M
M
M
H
H
H
H
H
H

H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
M
M
M
M
M
M
M
M
M
H
H
H
H
H
H

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