2006 04 Mechanical Integrity
2
DOW R ESTRICT ED - For intern al use on ly In 2004, process safety incidents reported to the Canadian Chemical Producers Association indicate that 25% were caused by problems with process equipment mechanical integrity. Further analysis of the same data shows that mechanical inte grity fa ilure is a cause of up to 50% of the incidents in several years between 1998 and 2003. ALL OF US are the first line of defense for plant integrity issues like the ones shown here. We are in the plant every day and have the opportunity to see and report these problems. “You can s ee a lot just by looking!” (Yogi Berr a, New York Yankees) Plan regular plant tours to look for mechanical integr ity problem s – such as corrod ed equipm ent, piping and valves, inadequate piping support, small drips or wet spots around flanges. Listen as well as look! For example, does that pump sound different? If so, perhaps maintenance should check it in case there is something wrong. P P rocess rocess S S afety afety B B eacon eacon http: //www.aiche.org/ccps/safetybeacon.htm Messages for Man ufacturing Personnel April 2006 CENTER FOR CHEMICAL PROCESS SAFETY AICh E © 2006. All rights reserved. Rep roduction for non-commercial, educati onal purposes is encouraged. However, reproduction for the purpose of resale by anyone other than CCPS is strictl y p rohibited. Contact us at [email protected] or 212-591 -7 319 S S The Beacon is usually available in Arabic, Chinese, Dutch, Engli The Beacon is usually available in Arabic, Chinese, Dutch, Engli sh, French, German, Hebrew, Hindi, Italian, Japanese, sh, French, German, Hebrew, Hindi, Italian, Japanese, Kor ean Portu ues e S an i sh an d T hai. Kor ean Portu ues e S an i sh an d T hai. Mechanical Integrity Sponsored by Sponsored by CCPS CCPS Supporters Supporters Did you know? What You Can Do BEFORE AFTER The flange on the left is badly corroded and the bolts are in very poor cond ition - a leak wa iting to happen. Fortunately, the poor condition was noted during a plant inspection and the flange was replaced (as shown on the right). The picture on the left shows a corroded control valve. Could you count on this valve to operate when you need it? The picture on the rig ht show s the replacement valve, which, if properly maintained and tested, is much more likely to function correctly when needed. This picture shows an improvised pipe support made from scaffolding, springs and clamps. But, don’t wa it for “official” plant safe ty tours and inspections. Be constantly aware of visual and other signs of equipment mechanical integrity problems. If you see or hear something that concerns you, report it promptly and follow-up to make sure steps are taken to correct the situation.
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Transcript of 2006 04 Mechanical Integrity
5/11/2018 2006 04 Mechanical Integrity - slidepdf.com
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DOW RESTRICTED - For internal use only
In 2004, process safety incidents reported to
the Canadian Chemical Producers Association
indicate that 25% were caused by problems
with process equipment mechanical integrity.
Further analysis of the same data shows tha
mechanical integrity failure is a cause of up to
50% of the incidents in several years between1998 and 2003.
ALL OF US are the first line of defense for
plant integrity issues like the ones shown here
We are in the plant every day and have the
opportunity to see and report these problems.
“You can see a lot just by looking!” (Yogi Berra, New York Yankees)
Plan regular plant tours to look for mechanical
integrity problems – such as corroded equipment,piping and valves, inadequate piping support, small
drips or wet spots around flanges.
Listen as well as look! For example, does that
pump sound different? If so, perhaps maintenance
should check it in case there is something wrong.
P Processrocess SSafetyafety B Beaconeaconhttp: //www.aiche.org/ccps/safetybeacon.htm
Messages for Manufacturing Personnel
April 2006
CENTER FOR
CHEMICAL PROCESS SAFETY
AIChE © 2006. All rights reserved. Reproduction for non-commercial, educational purposes is encouraged. However, reproduction
for the purpose of resale by anyone other than CCPS is strictly prohibited. Contact us at [email protected] or 212-591-7319
SS
The Beacon is usually available in Arabic, Chinese, Dutch, EngliThe Beacon is usually available in Arabic, Chinese, Dutch, English, French, German, Hebrew, Hindi, Italian, Japanese,sh, French, German, Hebrew, Hindi, Italian, Japanese,
Korean Portu uese S anish and Thai.Korean Portu uese S anish and Thai.
Mechanical Integrity
Sponsored bySponsored by
CCPSCCPS
SupportersSupporters
Did you know?
What You Can Do
BEFORE AFTER
The flange on the left is badly corroded and the bolts
are in very poor condition - a leak waiting to happen.Fortunately, the poor condition was noted during a
plant inspection and the flange was replaced (as shown
on the right).
The picture on the left shows a corroded control valve.
Could you count on this valve to operate when you
need it? The picture on the right shows the
replacement valve, which, if properly maintained and
tested, is much more likely to function correctly when
needed.
This picture shows an improvised pipe support
made from scaffolding, springs and clamps.
But, don’t wait for “official” plant safety
tours and inspections. Be constantly aware of visual and other signs of equipment mechanica
integrity problems.
If you see or hear something that concerns
you, report it promptly and follow-up to make
sure steps are taken to correct the situation.
5/11/2018 2006 04 Mechanical Integrity - slidepdf.com
http://slidepdf.com/reader/full/2006-04-mechanical-integrity 2/2
