Mechanical integrity testing

There are other equivalent tests which can show that the vessel is mechanically strong. For pumps, integrity data would involve the frequency of seal repairs, bearing repairs, nature and intensity of vibration, plugging, and corrosion problems. With the mechanical integrity tests, other data is recorded, such as records of inspections and tests, maintenance procedures, establishment of criteria for acceptable test results, and documentation of inspection results. Preventive maintenance (PM) programs are a big part of the PSM. 

Will mechanical integrity testing or inspections be impacted Yes No ... 

Process safety issues and concerns may come as a result of a process hazard analysis or revalidation, an incident investigation, an audit finding or a review of delays in required mechanical integrity tests and inspections. The appropriate priority must be... 

Implement scheduled nondestructive testing at key points to monitor corrosion as part of a mechanical integrity program... 

Some toll processes lend themselves to test runs in the pre-startup phase. Actual materials for the toll may be used in the test or substitute materials, typically with low hazard potential, are often used to simulate the charging, reaction, and physical changes to be accomplished in the toll. Flow control, temperature control, pressure control, mixing and transferring efficiency can be measured. Mechanical integrity can be verified in regard to pumps, seals, vessels, heat exchangers, and safety devices. 

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. 

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. 

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. 

Caliper surveying Caliper testing measures the diameter of the borehole. These measurements can also be used to determine the mechanical integrity of the well and the volume of concrete that is required... 

The evaluation and demonstration of this weldi ng technique was accomplished in three phases evaluation and optimization of ten major expl welding variables (plate material, plate thickness, explosive quantity standoff, plate surface, plate deformation, mechanical shock, metal grain orientation, weld length, and expl residual), the development of four welu joints, and an a fplicationai analysis which included photomicrographs, pressure integrity tests, vacuum effects, and fabrication of some potentially useful structures in aluminum and titanium... 

The repaired reboiler was mounted in the normal vertical position, when the employees decided to hydrostatically test the unit at the conclusion of the repairs. The mechanical integrity of the reboiler could be assured by a simple hydrotest. After the hydrotest pressure held and no leaks were detected, employees drained the water used to hydrotest from... 

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

The Role of Mechanical Integrity in Chemical Process Safety 233 Safety Relief Valve Testing and Repair Procedures... 

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