A-5 Mechanical Integrity Gruelich

7/23/2019 A-5 Mechanical Integrity Gruelich

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MechanicalIntegrityEssentials

BillGreulich

May

1,

2009


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SafetyMoment


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Regulations

FederalRiskManagementPrograms(RMP)for

ChemicalAccident

Prevention

Program,

40

CFR

68.73.

CaliforniaAccidentalReleasePrevention

Program(CalARP),

19

CCR

2760.5.

CaliforniaProcessSafetyManagement(PSM)of

AcutelyHazardous

Materials,

8CCR

5189(j).


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Definition

MechanicalIntegritymeanstheprocessof

ensuringthat

process

equipment

is

fabricatedfromthepropermaterialsof

constructionandisproperlyinstalled,

maintained,andreplacedtopreventfailures

andaccidental

releases.

19CCR2735.3


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BasicConcept

Youdesign,buildandinstallaprocessin

accordancewith

your:

ProcessSafetyInformation(PSI),

OperatingProcedures(SOPs),and,

Process

Hazard

Analysis

(PHA).YourMechanicalIntegrityprogramensuresit

continuestoperforminthewayyouinitially

intendeditto.


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Application

Pressurevesselsandstoragetanks;

Pipingsystems

(including

piping

components

suchasvalves);

Reliefandventsystemsanddevices;

Emergency

shutdown

systems; Controls(includingmonitoringdevicesand

sensors,alarms,andinterlocks);and,

Pumps.

19CCR2760.5(a)


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ProgramComponents

Writtenprocedures.

Trainingfor

maintenance

activities.

Inspectionandtesting.

Equipmentdeficiencies.

Quality

assurance.

19CCR2760.5(b)(f)


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WrittenProcedures

(A) Theemployershallestablishandimplementwrittenprocedures

tomaintaintheongoingintegrityofprocessequipmentand

appurtenances.These

procedures

shall

include

amethod:

1) forallowingemployeestoidentifyandreportpotentially

faultyorunsafeequipment;and

2) torecord

their

observations

and

suggestions

in

writing.

(B) Theemployershallrespondregardingthedispositionofthe

employee'sconcernscontainedinthereport(s)inatimely

manner.

(C) Theemployer

shall

provide

employees

and

their

representatives

accesstotheinformationrequiredinthissubsection.

8CCR5189(j)(1)


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Inspectionand

Testing

(A) Inspectionsandtestsshallbeperformedonprocessequipment.

(B) Inspectionandtestingproceduresshallfollowrecognizedand

generallyaccepted

good

engineering

practices.

(C) Thefrequencyofinspectionsandtestsshallbeconsistentwith

applicablemanufacturer'srecommendationsandgood

engineeringpracticesandmorefrequentlyifdetermined

necessaryasdictatedbyoperatinghistory.

(D) Theemployershallhaveacertificationrecordthateach

inspectionandtesthasbeenperformedinaccordancewiththis

subsection.Thecertificationshallidentifythedateofthe

inspection;thenameofthepersonwhoperformedthe

inspectionand

test;

and

the

serial

number

or

other

identifier

of

theequipment(also:adescriptionofthetestandtheresults).

8CCR5189(j)(2)


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EquipmentDeficiencies

Theemployershallcorrectdeficienciesin

equipment

which

are

outside

acceptable

limitsdefinedbytheprocesssafety

informationbeforefurtheruse,orinasafe

andtimelymannerprovidedmeansaretaken

toassure

safe

operation.

8CCR5189(j)(3)


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QualityAssurance

(A) Theemployershallassurethatintheconstructionof

newplantsandequipmentmodified,repaired,or

fabricatedequipment

is

suitable

for

the

process

applicationforwhichtheywillbeused.

(B) Appropriatechecksandinspectionsshallbe

performedasnecessarytoassurethatequipmentis

installedproperly

and

is

consistent

with

design

specificationsandmanufacturer'sinstructions.

(C) Theemployershallassurethatmaintenance

materials,sparepartsandequipment,meetdesign

specificationsand

applicable

codes.

8CCR5189(j)(4)


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SummaryMIensureswhatyousaidyourprocesswas

during

design,

fabrication,

and

installation

stillis!

MIismorethanamaintenance

program.

MIrequires

documented

inspection

and

testing.

MIdoesnottolerateindiscriminaterun

tofailure.

MItiestoPSI,PHA,SOP,PSSR,andMOC

requirements.

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