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Guidelines for Mechanical Integrity Systems

ISBN: 978-0-8169-0952-0
320 pages
August 2006
Guidelines for Mechanical Integrity Systems (0816909520) cover image
In recent years, process safety management system compliance audits have revealed that organizations often have significant opportunities for improving their Mechanical Integrity programs. As part of the Center for Chemical Process Safety's Guidelines series, Guidelines for Mechanical Integrity Systems provides practitioners a basic familiarity of mechanical integrity concepts and best practices. The book recommends efficient approaches for establishing a successful MI program.

Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.

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List of Tables.

List of Figures.

Items on the CD Accompanying this Book.

Acronyms and Abbreviations.

Glossary.

Acknowledgements.

Preface.

Management Overview of the Guidelines.

1. INTRODUCTION.

1.1 What is Mechanical Integrity?

1.2 Relationship to Other Programs.

1.3 Expectations for the MI Program.

1.4 The Effect of RAGAGEPs.

1.5 Structure of this Guidelines Book.

1.6 References.

2. MANAGEMENT RESPONSIBILITY.

2.1 Facility Leadership?s Roles and Responsibilities.

2.1.1 Organizational Roles and Responsibilities.

2.1.2 Roles and Responsibilities Matrix.

2.1.3 Reporting Mechanisms.

2.1.4 Auditing.

2.2 Technical Assurance Responsibilities.

2.2.1 Defining Acceptance Criteria.

2.2.2 Providing Technical Content.

2.2.3 Establishing Metrics.

2.2.4 Ensuring Technical Review.

3. EQUIPMENT SELECTION.

3.1 Reviewing Program Objectives.

3.2 Establishing Equipment Selection Criteria.

3.3 Defining Level of Detail.

3.4 Documenting the Equipment Selection.

3.5 Equipment Selection Roles and Responsibilities.

4. INSPECTION, TESTING, AND PREVENTIVE MAINTENANCE.

4.1 ITPM Task Planning.

4.1.1 ITPM Task Selection.

4.1.2 Developing Sampling Criteria.

4.1.3 Other ITPM Task Planning Considerations.

4.1.4 ITPM Task Scheduling.

4.2 Task Execution and Monitoring.

4.2.1 Defining Acceptance Criteria.

4.2.2 Equipment and ITPM Task Results Documentation.

4.2.3 ITPM Task Implementation and Execution.

4.2.4 ITPM Task Results Management.

4.2.5 Task Schedule Management.

4.2.6 ITPM Program Monitoring.

4.3 ITPM Program Roles and Responsibilities.

4.4 References.

5. MI TRAINING PROGRAM.

5.1 Skills/Knowledge Assessment.

5.2 Training For New and Current Workers.

5.3 Verification and Documentation of Training Effectiveness.

5.4 Certification.

5.5 Ongoing and Refresher Training.

5.6 Training for Technical Personnel.

5.7 Contractor Issues.

5.8 Roles and Responsibilities.

5.9 References.

6. MI PROGRAM PROCEDURES.

6.1 Types of Procedures Supporting the MI Program.

6.2 Identification of MI Procedure Needs.

6.3 Procedure Development Process.

6.4 MI Procedure Format and Content.

6.5 Other Sources of MI Procedures.

6.6 Implementing and Maintaining MI Procedures.

6.7 Procedure Program Roles and Responsibilities.

6.8 References.

7. QUALITY ASSURANCE.

7.1 Design.

7.2 Procurement.

7.3 Fabrication.

7.4 Receiving.

7.5 Storage and Retrieval.

7.6 Construction and Installation.

7.7 In-service Repairs, Alterations, and Rerating.

7.8 Temporary Installations and Temporary Repairs.

7.9 Decommissioning/Reuse.

7.10 Used Equipment.

7.11 Spare Parts.

7.12 Contractor-Supplied Equipment and Materials.

7.13 QA Program Roles and Responsibilities.

7.14 References.

8. EQUIPMENT DEFICIENCY MANAGEMENT.

8.1 Equipment Deficiency Management Process.

8.2 Acceptance Criteria.

8.3 Equipment Deficiency Identification.

8.4 Responding to Equipment Deficiencies.

8.5 Equipment Deficiency Communication.

8.6 Permanent Correction of Equipment Deficiencies.

8.7 Deficiency Management Roles and Responsibilities.

8.8 Reference.

9. EQUIPMENT-SPECIFIC INTEGRITY MANAGEMENT.

9.1 Fixed Equipment.

9.2 Relief and Vent Systems.

9.3 Instrumentation and Controls.

9.4 Rotating Equipment.

9.5 Fired Equipment.

9.6 Electrical Systems.

9.7 Fire Protection Systems.

9.8 Miscellaneous Equipment.

9.8.1 Ventilation and Purge Systems.

9.8.2 Protective Systems.

9.8.3 Solids-handling Systems.

9.8.4 Safety-critical Utilities.

9.8.5 Other Safety Equipment.

9.9 References.

10. MI PROGRAM IMPLEMENTATION.

10.1 Budgeting and Resources 183.

10.1.1 Program Development Resources.

10.1.2 Initial Implementation Resources.

10.1.3 Ongoing Efforts.

10.2 Use of Software in MI Programs.

10.2.1 Use of CMMS.

10.2.2 Other Software Used in MI Programs.

10.3 Return on Investment (ROI).

10.3.1 Improved Equipment Reliability.

10.3.2 Cost Avoidance.

10.3.3 Regulatory Compliance and Industry Association Commitments.

10.3.4 Reduced Liability and Reduced Damage to Corporate Reputation.

10.4 References.

11. RISK MANAGEMENT TOOLS.

11.1 Introduction to Common Risk-based Analytical Techniques Used in MI Programs.

11.2 Incorporating Risk into MI Decisions.

11.3 FMEA/FMECA.

11.4 RCM.

11.5 Risk-based Inspection.

11.5.1 Equipment and Process Data.

11.5.2 Risk Modeling.

11.5.3 Inspection Planning Strategies/Guidelines.

11.5.4 Other RBI Program Issues.

11.6 Protection Layer Analysis Techniques.

11.7 References.

12. CONTINUOUS IMPROVEMENT OF MI PROGRAMS.

12.2 Program Audits.

12.3 Performance Measurement and Monitoring.

12.4 Equipment Failure and Root Cause Analyses.

12.4.1 Failure Analysis.

12.4.2 Root Cause Analysis.

12.5 References.

Index.

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Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology.  CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 80 books in its process safety guidelines and process safety concepts series.

A team of CCPS member volunteer experts guided the development of this book, which was compiled by Randal Montgomery and Andrew Remson under contract. Messrs. Montgomery and Remson have helped facilities develop and implement MI programs and have instructed hundreds of engineers and process safety professionals on the topic.

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"…an excellent overview of all aspects of mechanical integrity systems…should be very useful for any engineer…" (Journal of Loss Prevention in the Process Industries, January 2007)

"…a thorough introduction to MI Systems for managers, quality control engineers and those who are responsible for maintaining systems." (E-STREAMS, September 2007)

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