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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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