Mechanical integrity equipment

The discussion below excludes column inspection for identifying corrosion, fatigue, and conditions that lead to deterioration of equipment mechanical integrity. These inspections should be performed separately by personnel specifically trained in these disciplines. The inspection emphasized here should be carried by the operations or process personnel. 

When water or steam is used as a utility, insure appropriate mechanical integrity program for equipment... 

Cyclic nature of Implement mechanical integrity program batch process (e.g.,, Design equipment for easy replacement start/stop, thermal cycling). Possibil- Consider demand of cycling while designing ity of mechanical equipment and controls wear and tear. Possible loss of containment. ... 

Erequent start/stop Minimize frequent start/stop by proper sizing of of equipment may equipment (e.g. pump capacity) lead to equipment, Implement mechanical integrity program failure. Develop procedure to investigate causes for frequent reset of control Minimize frequent start/stop of equipment ... 

External corrosion Implement mechanical integrity program of high-energy, Implement proper selection of material of equipment. Loss construction of containment and damage due to flying debris. CCPS G-23 CCPS G-29 CCPS G-39... 

Has the facility established an effective critical-equipment maintenance program (also termed mechanical integrity program) to prevent failures that would cause hazardous conditions ... 

Test run steps can frequently be incorporated into process startup procedures. Two examples would be pulling a vacuum on vessels and verifying it holds, or distilling a solvent and checking for the presence of water to verify the mechanical integrity of the heating and cooling equipment. 

Did not establish and implement written procedures to maintain mechanical integrity of process equipment. 

Mechanical integrity An element of process safety focused on ensuring that equipment is designed, installed, and maintained to perform the desired function. 

When the discs are of the shrunk-on design, they are made up individually and stacked onto the shaft by first heating the disc to dilate the bore. They are then allowed to cool and thus attach themselves to the shaft. Keys are normally not used. When the discs are of the stacked design, the discs are equipped with rabbet fit to radially lock the discs to maintain concentricity of assembly. The through-bolts are usually tensioned by stretching hydraulically to a precise value to ensure the mechanical integrity of the assembly. 

Equipment used to process, store, or handle highly hazardous chemicals must be designed constructed, installed and maintained to minimize the risk of release. A systematic, scheduled, test and maintenance program is preferred over "breakdown" maintenance " that could compromise safety. Elements of a mechanical integrity program include 1) identification and categorization of equipment and instrumentation, 2) documentation of manufacturer data on mean time to failure, 3 ) test and inspection frequencies, 4) maintenance procedures, 5) training of maintenance personnel, 6) test criteria, and 7) documentation of test and inspection results. 

This phase involves the performance of check-out and nm-in activities to ensure that equipment and piping are mechanically integrated, functionally located and free of obstructions It is also necessary to ensure that instruments and controls are fimchoning properly and that all previously identified problems have been addressed. All maintenance and operating procedures need to be verified as correct. 

The mechanical integrity section of the PSM standard ensures that the equipment, piping, relief systems, controls, and alarms are mechanically sound and operational. The requirements include (1) written procedures to maintain functioning systems, (2) training regarding preventive maintenance, (3) periodic inspections and testing based on vendor recommendations, (4) a process to correct deficiencies, and (5) a process to ensure that all equipment and spare parts are suitable. 

Process Safety Review Procedures for Capital Projects Process and Equipment Integrity Human Factors Company Standards, Codes, and Regulation Employee Participation Pre-Startup Safety Review Mechanical Integrity Hot Work Permit Emergency Planning and Response Trade Secrets Planning for Emergencies... 

Maintenance includes athorough check of equipment or a device to give maximum assurance that the equipment or device will operate effectively and safely. It may be necessary to disassemble and reassemble the equipment or device to ensure a through examination. Maintenance procedures should follow manufacture s recommended guidelines or accepted practices developed by recognized authorities, such as NFPA. Documentation of maintenance activities should be part of the facility s mechanical integrity program and all documentation should be part of the equipment history file. 

Review the rest of the mechanical integrity program to ensure all critical equipment, piping, and pumps have acceptable integrity and an established inspection program with guidelines for repair. Include inspection and repair of fireproof insulation in the program. (By March 2002)... 

---