MechanicalIntegrityEssentials

BillGreulich
May1,2009

SafetyMoment

Regulations
FederalRiskManagementPrograms(RMP)for
ChemicalAccidentPreventionProgram,40CFR
68.73.
CaliforniaAccidentalReleasePrevention
Program(CalARP),19CCR2760.5.
CaliforniaProcessSafetyManagement(PSM)of
AcutelyHazardousMaterials,8CCR5189(j).

Definition
MechanicalIntegritymeanstheprocessof
ensuringthatprocessequipmentis
fabricatedfromthepropermaterialsof
constructionandisproperlyinstalled,
maintained,andreplacedtopreventfailures
andaccidentalreleases.
19CCR2735.3

BasicConcept
Youdesign,buildandinstallaprocessin
accordancewithyour:
ProcessSafetyInformation(PSI),
OperatingProcedures(SOPs),and,
ProcessHazardAnalysis(PHA).
YourMechanicalIntegrityprogramensuresit
continuestoperforminthewayyouinitially
intendeditto.

Application
Pressurevesselsandstoragetanks;
Pipingsystems(includingpipingcomponents
suchasvalves);
Reliefandventsystemsanddevices;
Emergencyshutdownsystems;
Controls(includingmonitoringdevicesand
sensors,alarms,andinterlocks);and,
Pumps.
19CCR2760.5(a)

ProgramComponents

Writtenprocedures.
Trainingformaintenanceactivities.
Inspectionandtesting.
Equipmentdeficiencies.
Qualityassurance.
19CCR2760.5(b)(f)

WrittenProcedures
(A) Theemployershallestablishandimplementwrittenprocedures
tomaintaintheongoingintegrityofprocessequipmentand
appurtenances.Theseproceduresshallincludeamethod:
1) forallowingemployeestoidentifyandreportpotentially
faultyorunsafeequipment;and
2) torecordtheirobservationsandsuggestionsinwriting.
(B) Theemployershallrespondregardingthedispositionofthe
employee'sconcernscontainedinthereport(s)inatimely
manner.
(C) Theemployershallprovideemployeesandtheirrepresentatives
accesstotheinformationrequiredinthissubsection.
8CCR5189(j)(1)

InspectionandTesting
(A) Inspectionsandtestsshallbeperformedonprocessequipment.
(B) Inspectionandtestingproceduresshallfollowrecognizedand
generallyacceptedgoodengineeringpractices.
(C) Thefrequencyofinspectionsandtestsshallbeconsistentwith
applicablemanufacturer'srecommendationsandgood
engineeringpracticesandmorefrequentlyifdetermined
necessaryasdictatedbyoperatinghistory.
(D) Theemployershallhaveacertificationrecordthateach
inspectionandtesthasbeenperformedinaccordancewiththis
subsection.Thecertificationshallidentifythedateofthe
inspection;thenameofthepersonwhoperformedthe
inspectionandtest;andtheserialnumberorotheridentifierof
theequipment(also:adescriptionofthetestandtheresults).
8CCR5189(j)(2)

EquipmentDeficiencies
Theemployershallcorrectdeficienciesin
equipmentwhichareoutsideacceptable
limitsdefinedbytheprocesssafety
informationbeforefurtheruse,orinasafe
andtimelymannerprovidedmeansaretaken
toassuresafeoperation.
8CCR5189(j)(3)

QualityAssurance
(A) Theemployershallassurethatintheconstructionof
newplantsandequipmentmodified,repaired,or
fabricatedequipmentissuitablefortheprocess
applicationforwhichtheywillbeused.
(B) Appropriatechecksandinspectionsshallbe
performedasnecessarytoassurethatequipmentis
installedproperlyandisconsistentwithdesign
specificationsandmanufacturer'sinstructions.
(C) Theemployershallassurethatmaintenance
materials,sparepartsandequipment,meetdesign
specificationsandapplicablecodes.
8CCR5189(j)(4)

Summary
MIensureswhatyousaidyourprocesswas
duringdesign,fabrication,andinstallation
stillis!
MIismorethanamaintenance
program.
MIrequiresdocumentedinspectionand
testing.
MIdoesnottolerateindiscriminaterun
tofailure.
MItiestoPSI,PHA,SOP,PSSR,andMOC
requirements.