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Mechanical Integrity - doe-hdbk-1101-20040087
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Process Safety Management for Highly Hazardous Chemicals - index
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DOE-HDBK-1101-2004
Equipment in contact with HHCs forms the first line of defense in preventing uncontrolled
catastrophic HHC releases. The second line of defense is typically a combination of containment
and safety systems. For example, controlled releases of chemicals may be made to surge or
overflow tanks, to diked areas or controlled drainage systems, or through pressure relief valves
or vents to scrubbers, filtration systems, or flares. Second line systems also include chemical
detection systems and fire detection and suppression systems. The mechanical integrity program
must ensure that components in both primary and secondary lines of defense are designed,
installed, and operated properly.
Corresponding DOE Programs and Requirements
Most contractors already have preventative maintenance programs for their facilities. These
programs must comply with maintenance management requirements contained in DOE O
420.1A, FACILITY SAFETY, and DOE O 430.1B, REAL PROPERTY ASSET
MANAGEMENT which address most requirements of the Mechanical Integrity element with
little modification. DOE's quality assurance program described in DOE O 414.1A Chg 1,
QUALITY ASSURANCE and DOE G 414.1-2, QUALITY ASSURANCE MANAGEMENT
SYSTEM GUIDE FOR USE WITH 10 CFR 830.120 AND DOE O 414.1A Chg 1 helps to
ensure that process equipment meets specifications and is properly installed. Configuration
control and management requirements found in DOE O 430.1B also help ensure the mechanical
integrity of process equipment. The DOE safety analysis process can help to focus mechanical
integrity programs on safety critical systems, components, and structures.
Documentation Requirements
Written procedures are required for maintenance operations including the inspection, testing,
maintenance, and repair of process equipment. Inspections and tests must be documented and
must include the date, the name of the person performing the inspection or test, identification of
the equipment examined or tested, the nature of the test or inspection, and results. Deficiencies
must be corrected before the equipment is returned to service, or it must be tracked to ensure that
corrective action is taken in a safe and timely manner. A system must be in place to track,
address, and close out deficiencies identified during inspection and testing. Routine maintenance
activities should also be documented.
Documentation of the training of maintenance workers on the process, related hazards, and
applicable procedures should be consistent with documentation requirements noted in Section
2.5.
Minimum Implementation Criteria
Maintenance and quality assurance programs are crucial for fabrication, installation, and repair
of process equipment. When inspection and testing identify conditions outside of safety limits,
deficiencies must be repaired before operations are resumed. If it is not possible to stop
operations, actions must be taken to ensure safe operations so that corrective actions can be made
in a safe and timely manner. The program to ensure the mechanical integrity of process
equipment should contain:
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