Mechanical integrity inspection

The percentage of mechanical integrity inspections performed on time... 

Are tests for safety critical process instrumentation completed on time Are mechanical integrity inspections completed on time ... 

Any identified deficiencies must be addressed. This means that a budget should be prepared to take care of those items that will require attention following the Mechanical Integrity inspections. 

Bragatto, P.A., Pittiglio, P., Ansaldi, S. 2009 The management of mechanical integrity inspections at small-sized Seveso faciXitiesReliabilityEng. System Safety, 94(2), pp. 412—417. 

OSHA s Process Safety Management standard requires that mechanical integrity inspections have to be documented (including the name of the person performing the inspection or test) and list the information to be recorded. 

Inherently safer principles also apply to mechanical integrity requirements. Design plant modifications for ease and reduced risk in inspections, code compliance, and maintenance. For example, if one can check the pipe thickness from a platform, it is more likely to be done than if a crane is required. 

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 section discusses inspection and maintenance practices and procedures that affect the mechanical integrity of flame arrester installations. 

Identifying and implementing possible improvements in mechanical integrity programs, such as increasing inspection frequencies for piping in corrosive or erosive service... 

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. 

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)... 

Clearly define a process for delaying maintenance and capital work in the event of budget constraints. Critical repair work should not be delayed. Environmental, Safety, and Health reviews should be conducted on delay of scheduled mechanical integrity program inspections. (Before startup)... 

Once the pass partition baffle fails, the process fluid may bypass the finned tubes, and cooling efficiency is greatly reduced. This is bad. But worse yet, during a turnaround of the cooler, there is normally no way to inspect the pass partition baffle. There is no easy way to visually verify the mechanical integrity of this baffle. A few air coolers have removable inspection ports for this purpose most do not. 

Offers an industry view of mechanical integrity and details on inspections and tests... 

Mr. Ken Robertson, President of Exxon Chemical Americas, discussed protective programs or mechanical integrity programs in a keynote address at the Chemical Manufacturer Association s Plant Inspection and Maintenance Forum in 1990. Indicating... 

The Role of Mechanical Integrity in Chemical Process Safety 219 Internal Inspections of Vessels... 

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