INTRODUCTION
Mechanical
Integrity is the programmatic implementation of activities necessary to ensure
that important equipment will be suitable for its intended application
throughout the life of an operation. MI programs vary according to industry, regulatory
requirements, geography and plant culture. A practical MI program will fit
within a facility’s existing process safety and RMPs as well as other
improvement initiatives (e.g., reliability, quality). Quality assurance of the
Mechanical Integrity program begins with the procurement of reputable
engineering firms that design the facility and its layout and selection of
fabrication/installation contractors that construct and assemble the equipment
and systems on the structure. It continues when vendors, manufacturers and/or
production personnel calibrate and commission the facility. Personnel charged
with developing and administering the MIQA program can optimize the process by
taking advantage of existing programs and by knowing which people and groups of
people are responsible for related activities. Reliability-Centered Maintenance
(RCM) is a tool used to achieve desired system output with optimal maintenance
input. RCM is a systematic, logical approach to prioritize and assign
preventive maintenance (PM) tasks that are applicable (i.e., can truly reduce
failure potential) and effective (i.e., are worth doing).
MIQA
interfaces with other safety element :
- Equipment Reliability: An MIQA program is the foundation of a plant’s
reliability program. Reliability program activities (e.g., vibration
monitoring, equipment quality control) contribute to MIQA.
- Workforce Involvement: Employees from various departments have input into the
MIQA program.
- Operating Procedures: Operating procedures may cover MIQA-related
activities, such as equipment surveillance as part of operator rounds,
reporting operating anomalies, recording historical equipment
operating data and preparing equipment for maintenance.
- Hazard Identification and Risk Analysis: HIRAs, also known as process hazard analyses
(PHAs), can help define the equipment scope for the MIQA program
and prioritize MIQA activities. MIQA history can help HIRA teams
determine the adequacy of safeguards.
- Management of Change (MOC): MOC applies to MIQA activities and documents (e.g., new
or modified equipment, changes to task frequencies and procedures). MOC
review teams can include process and MIQA personnel. The MOC program may
be upgraded to help manage equipment deficiencies.
- Emergency Management: Emergency response equipment needs to be inspected and
maintained.
- Incident Investigation: MIQA records may be needed by investigation teams and
Investigation recommendations may impact MIQA activities.
- Training: MIQA
training is an overview of the process and its hazards can be consistent
with the content of the operator training program.
Safety Incidents Relevance Forty-six percent of the largest losses in facilities are
due to the failure of one PSM program element — mechanical integrity. The most
recent update shows piping failures and leaks, cryogenic plant equipment
failure, and weather conditions as major causes.
Safety Incidents due to QA failure There is a lot of issues involving mechanical integrity such
as design failure, fabrication failure, maintenance failure, equipment
deficiency management and others.
Incidents due to Procurement failure
Use of a liquid chlorine transfer
hose made of similar-looking stainless steel braid instead of Hastelloy C led
to corrosion and hose failure resulting in a (22,000 kg) chlorine release
during railcar unloading. Both user and hose vendor quality management systems
were found to be inadequate.
Incident during equipment delivery A vendor made a change to a gasket on a gaseous chlorine
strainer. The gasket was now designed for a new strainer model. The vendor
updated its specification; however, a user of the older model strainer was not
notified of the change by the vendor. The difference in gaskets was not caught
during receiving. Installers noticed that the new strainer gasket was different.
It subsequently failed a leak test.
Benefits
An MIQA program can expect benefits
in the following areas:
- Safety of people, technology & business
- Asset reliability
- Cost avoidance (including safety, environmental, and
financial costs)
- Regulatory compliance and industry association
commitments
- Reduced liability and reduced damage to corporate
reputation
No comments:
Post a Comment