Process equipment mechanical integrity

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. 

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. ... 

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. 

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. 

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... 

The mechanical integrity focus of this section covers stationary existing chemical processing plant equipment and piping. Equipment includes storage tanks, pressure vessels, dryers, heat exchangers, reactors, incinerators, columns, filters, knock-out pots, and so forth. As previously stated, this section assumes the equipment is designed and fabricated to... 

The intent of the mechanical integrity section of the OSHA Process Safety Law is to prevent or reduce catastrophic releases. [1] An equipment classification system is a requirement of the law. Earlier in the chapter, a simple system involving three classes was previously defined. Here are the highlights of that section specifically for pressure vessels and storage tanks. 

---