4 Mechanical Integrity
4 Mechanical Integrity
Accidents
Mechanical Integrity
Preventing Maintenance Breakdowns
This material was produced under grant SH-17813-08-60-F-34 from the Occupational Safety and
Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or
policies of the U.S. Department of Labor, nor does mention of trade names, commercial products,
or organizations imply endorsement by the U.S. Government. This curriculum is revised from
materials originally developed by the United Steelworkers Tony Mazzocchi Center for Safety,
Health, and Environmental Education and produced by the Steelworkers Charitable and
Educational Organization, funded in whole or in part with funds from the Occupational Safety and
Health Administration, U.S. Department of Labor (grant number SH-16632-07-60-F-42).
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Table of Contents
About WEC iii
Preventing Chemical Accidents iv
The Small Group Activity Method v
The Factsheet Reading Method vii
Mechanical Integrity -
Preventing Maintenance Breakdowns 1
Task 1 2
Task 2 13
Evaluation 25
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
About WEC
The New Jersey Work Environment Council (WEC) is a non-profit
collaboration of organizations working for safe, secure jobs, and a
healthy, sustainable environment.
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Basic Structure
The Small Group Activity Method* is based on a series of problem-
solving activities. An activity can take from 45 minutes to an hour.
Each activity has a common basic structure:
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
*The Small Group Activity Method (SGAM) is based on a training procedure developed by
Englands Trades Union Congress (TUC) in the 1970s. The Labor Institute and Oil, Chemical,
and Atomic Workers Union (now part of the United Steelworkers Union) used a similar
method around economic and health and safety issues for workers and further developed
the procedure into SGAM. The New Jersey Work Environment Council has used SGAM since
1986.
Worker-to-Worker
Worker-to-Trainer
Trainer-to-Worker
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Starting with the scribe and moving to the left, count out loud
from 1 to 8. Keep going around the table until all numbers
(factsheets) are distributed. For example, if there are four people
at your table, the scribe will have self-assigned Factsheets 1 and
5; the person to their left will have Factsheets 2 and 6, etc. The
assigned numbers correspond to Factsheets 1 through 8 on the
following pages.
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Mechanical Integrity -
Preventing Maintenance Breakdowns
Purposes
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Task 1
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Factsheet #1
Maintenance Myths Most Often Heard
The buyer insisted on the test even with the added expense. The
smoke detectors worked but when the explosive charge was
activated, the rupture disc was not activated. The manufacturer
was in error.
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Factsheet #1 (continued)
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Sources: Accident at Amoco Chemicals related by Glenn Erwin, Health and Safety
Coordinator, OCAW (now USW); and Trevor A. Kletz, What Went Wrong? Case Histories of
Process Plant Disasters, Houston: Gulf Coast Publishing Company, Second Edition,
November 1989.
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Factsheet #2
Work Order Backlog: #1 Warning Sign
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Factsheet #3
If It Aint Broke . . .
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Source: Total Productive Maintenance, Marshall Institute, Inc. (2900 Yonkers Road, Raleigh,
NC).
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Factsheet #4
Understaffing Leads to Problems: A Case
Study
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Factsheet #4 (continued)
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Preventing Chemical Accidents: Mechanical Integrity Preventing Maintenance Breakdowns
Source: Testimony given before OSHA from USW member Jimmy Herrington, Local 4-243,
February 24, 1991 [Emphasis added]; U.S. Chemical Safety and Hazard Investigation Boards
Investigation Report: Refinery Explosion and Fire, Report No. 2005-04-1-TX, March, 2007.
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Factsheet #5
Maintenance Downsizing
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Sources: U.S. Department of Labor, Handbook of Employment and Earnings U.S. Labor
Statistics, ninth edition, Lanham, MD: Bernan Press, March 2008; and U.S. Census Bureau,
Statistical Abstract of the United States: 2006.
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Factsheet #5 (continued)
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Sources: U.S. Department of Commerce, Survey of Current Business, June issues; Garrison,
W. E., PE, Large Property Damage Losses in the Hydrocarbon-Chemical Industries: A Thirty-
Year Review, Twelfth Edition, Chicago: Marsh and McLennan Protection Consultants; and The
100 Largest Losses: 1972-2001, Twentieth Edition, 2003.
Factsheet #6
Longer Time between Turnarounds Leads to
Danger
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Source: USW member Jimmy Herrington, Local 4-243, testimony before OSHA, February 24,
1991.
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Task 2
Scenario:
Jim filled out the work order and gave it to his Foreman, Bob.
Bob made a notation in the unit log book that the bearings were
bad and forwarded the work order to the unit supervisor for
approval. Bob and his crew were finishing up their night rotation
and were starting their days off.
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Task 2 (continued)
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Factsheet #1
The PSM Standard Is Performance-based
A Review from the Introduction to PSM
Activity
Performance-based Standards
The PSM Standard gives each facility the flexibility to design its
own program to match its needs, as long as the outcome prevents
or minimizes major releases, spills, fires, and explosions.
(Specification-based OSHA standards prescribe precise rules, such
as a guardrails height, exact limits of exposure, etc.)
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Factsheet #1 (continued)
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Factsheet #2
What the PSM Standard Covers
6. Pumps.
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Source: OSHA Process Safety Management Standard 29 CFR 1910.119, 57 FR 6406,
February 24, 1992.
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Factsheet #3
OSHAs Elements for an MI Program
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Source: OSHA Process Safety Management Standard, 29 CFR 1910.119, 57 FR 6356,
February 24, 1992.
Factsheet #4
Why Preventive Maintenance?
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Factsheet #4 (continued)
It Pays.
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Sources: Federal Register, Vol. 58, No. 201, October 20, 1993; Consolidated Rule Document
2009, Toxic Catastrophe Prevention Act; Ray Brandes, retired director of safety for ICI
Americas; and U.S. Chemical Safety and Hazard Investigation Board Investigation Report:
Refinery Explosion and Fire, Report No. 2005-04-1-TX, March 2007.
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Factsheet #5
Not All Employees Receive the Same Safety
Training
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Source: John Gray Institute, Managing Workplace Safety and Health: The Case of Contract
Labor in the U.S. Petrochemical Industry, Lamar University System, July 1991, p. 77.
Factsheet #6
Maintenance Failures Can Have Terrible
Results
This list illustrates just a few examples of the human cost to both
workers and the community caused by failure to properly
maintain process equipment.
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Overfilled vessel: (Blowdown drum)
March 2005 A blast at the BP Texas City refinery which killed 15
and injured 180 people followed budget cuts of 25 percent from
1998 to 2000 at the plant. A blowdown drum overfilled and
alarms and gauges that were supposed to warn of the problem
did not work properly.
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Summary: Mechanical Integrity
1. Preventive maintenance programs should be established,
funded and staffed to sufficient levels to avoid the need for
breakdown maintenance.
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Preventing Chemical Accidents
Process Safety Management Training from the NJ Work Environment
Council
PROGRAM EVALUATION FORM
Knowledge of subject
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More on back.
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5. How could this activity be improved?
Additional Comments:
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