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Mechanical Integrity Program Description

The Mechanical Integrity Program is developed to protect health, safety, the environment, and equipment reliability through scheduled inspections and testing. It applies to processes handling hazardous chemicals and includes pressure vessels, piping, storage tanks, and pressure relief devices. The program involves developing inspection and testing plans, performing inspections and non-destructive examinations, identifying deficiencies, and updating equipment records. Implementation of the program is the responsibility of the Maintenance and Reliability Engineering department under the direction of the Mechanical Integrity Supervisor.

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1K views3 pages

Mechanical Integrity Program Description

The Mechanical Integrity Program is developed to protect health, safety, the environment, and equipment reliability through scheduled inspections and testing. It applies to processes handling hazardous chemicals and includes pressure vessels, piping, storage tanks, and pressure relief devices. The program involves developing inspection and testing plans, performing inspections and non-destructive examinations, identifying deficiencies, and updating equipment records. Implementation of the program is the responsibility of the Maintenance and Reliability Engineering department under the direction of the Mechanical Integrity Supervisor.

Uploaded by

camasa2011
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Mechanical Integrity Program Description

1.0 PURPOSE
To provide an overview of the Mechanical Integrity Program, which has been
developed for use by the Host Company in order to protect the environment,
human lives, property, and reliability through scheduled inspections. The Mechanical
Integrity Program details how the risk of release of hazardous chemicals into the
atmosphere can be reduced, how equipment efficiency can be improved, and
ultimately improve the quality of product being produced.
2.0 SCOPE
2.1 This Mechanical Integrity Program applies to processes which handle hazardous
chemicals as defined by OSHA 29 CFR 1910.119 and applies to:

Pressure Vessels - covered by API 510


Piping Components covered by API 570
Storage Tanks covered by API 653
Pressure Relieving Devices covered by API 576

2.2 This procedure provides an overview of the actions and inspection activities,
which must be accomplished on the above equipment to meet the objectives of this
Mechanical Integrity Program. The Program is grouped in the following categories:

Mechanical Integrity Program


Administrative Procedures
Inspection Procedures
NDE Procedures

3.0 RESPONSIBILITY
The Host Company Maintenance and Reliability Engineering, under direction of the
Mechanical Integrity Site Supervisor, are responsible for the execution of the
Mechanical Integrity Program. Included in those responsibilities are:
Establish or adopt inspection, testing, and documentation for existing equipment,
repaired or modified equipment, and new equipment being added to process.
Implement the Mechanical Integrity Program.
Take corrective action with equipment deficiencies.
Maintaining and updating program documentation.
4.0 DEFINITIONS
Administrative Procedures - Documents, which control the development and
management of the Mechanical Integrity Program. Included are procedures for
preparation and control of documents, managing data and reports, training,
planning and scheduling.
Equipment File - A centrally located file for each equipment item which contains
copies of the manufactures U-1s, construction drawings, Highlighted P&ID, Piping
line list, field or ACAD drawings, Inspection and NDE Reports, Nonconformance and
Deficiency Correction reports. This file is the working file for Mechanical Integrity
Program data.
Inspection Procedures - Documents, which describe the method for developing
and carrying out Inspections specific to each type of equipment. An Inspection
Procedure is used within a department and gives the certified Inspector(s) the
steps, information, and safety requirements needed to perform the Inspection task.
Master File is the file for each equipment item included in the Mechanical
Integrity Program, which contain the final Inspection and NDE Reports, closed
Nonconformance Reports, highlighted P&IDs, line list (if pipe package), and ACAD
drawings.

Maintenance Data Management System - The electronic system for managing


the Mechanical Integrity Program. It contains the data from the equipment files,
tracks scheduled activities, and correction of deficiencies.
Mechanical Integrity Program - The management system that defines the tests,
inspections, and maintenance procedures at the Host Company to assure that
equipment has been designed, constructed, installed, and maintained. These
documents include the description of the Mechanical Integrity Program and the
components of the process.
MSDS Material Safety Data Sheet is a summary of health, safety, and
environmental information on a chemical or mixture of ingredients.
NDE Procedure - Documents that establish the responsibility, authority, and the
acceptable method for performing a given Non Destructive Examination task.
An NDE Procedure is used within a department and gives the Level I or II
Technician the steps, information, and safety requirements needed to perform the
task.
P&ID Is the Piping and Instrument Diagram, which the Host Company supplies.
The P&ID identifies the piping and includes line numbers, piping diameters, flow
directions, valves etc.
Piping Circuit - A section of piping that has all points exposed to an environment
of similar corrosivity and that is of similar design conditions and construction
material. Complex process units or piping systems are divided into piping circuits to
manage the necessary inspections, calculations, and record keeping.
Process Flow Diagram is a client supplied drawing identifying the major
equipment, processes, and process flows in an operating unit and also include
process variables such as operating temperature and operating pressure.
Tracking List is a list of equipment items, by equipment type and unit, included
in the Mechanical Integrity Program.
5.0 PROCEDURE
5.1 Obtain current and updated P&IDs, Process Flow Diagrams, and MSDS sheets
from the Host Company.
5.2 Develop a tracking list, by unit, of all equipment, piping, and PSVs to be
inspected.
5.2.1 The piping must be grouped by system before the tracking list can be made.
5.3 Assemble a folder with data for the equipment, piping, and PSVs, which
includes the following:
Manufacturers U-1 form
Manufacturer drawings
Repair history
Data Sheets
Inspection and testing worksheet
Inspection Reports
NDE Reports
Highlighted P&ID of what was inspected
Nonconformance Report if applicable
Piping line list (if piping package)
Field or ACAD drawings, whichever were available at the time of inspection.
5.4 Identify potential problems based on the Inspection Procedures and past
experience with the equipment, piping, or PSV.
5.5 Select the Inspection Procedure, which address the potential problems and
develop an Inspection and Testing Plan worksheet.
5.6 Schedule the activities, i.e. field sketch, external visual inspection, NDE, for the
assigned Inspector or Technician and document the results of the inspection.
Compare the inspection results with the Code, standard, or acceptance criteria.
5.7 The Inspector will give the inspection documentation, with TML assignment,
data, and the hand sketches of the equipment or piping to the Site Supervisor for
review.

5.8 The Site Supervisor will send the documentation to the Data Entry Clerk, who
will enter the information into the Maintenance Data Management System. The
original inspection report with NDE data will be stored in the equipment files.
5.9 The Site Supervisor will give the hand sketches of the equipment or piping, with
TML data, to the ACAD assigned person, who will perform those activities and print
the completed drawing, with assigned TMLs, and the drawing will be stored in the
equipment files.
5.10 Update the inspection and testing plan.
5.11 Once all the necessary work is completed for the selected piece of equipment,
the equipment file folder will be sent to the master file at the Host Company.
6.0 REFERENCES
6.1 OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous
Chemicals.

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