Mechanical Integrity - doe-hdbk-1101-20040087

DOE-HDBK-1101-2004

2.8 Mechanical Integrity

29 CFR 1910.119 (j)

(1)

Application. Paragraphs (j)(2) through (j)(6) of this section apply to the following process equipment:

(i) Pressure vessels and storage tanks;

(ii) Piping systems (including piping components such as valves);

(iii) Relief and vent systems and devices;

(iv) Emergency shutdown systems;

(v) Controls (including monitoring devices and sensors, alarms, and interlocks) and,

(vi) Pumps.

(2)

Written procedures. The employer shall establish and implement written procedures to maintain the ongoing

integrity of process equipment.

(3)

Training for process maintenance activities. The employer shall train each employee involved in

maintaining the on-going integrity of process equipment in an overview of that process and its hazards and

in the procedures applicable to the employee's job tasks to assure that the employee can perform the job

tasks in a safe manner.

(4)

Inspection and testing.

(i)

Inspections and tests shall be performed on process equipment.

(ii)

Inspection and testing procedures shall follow recognized and generally accepted good

engineering practices.

(iii)

The frequency of inspections and tests of process equipment shall be consistent with applicable

manufacturer's recommendations and good engineering practices, and more frequently if

determined to be necessary by prior operating experience.

(iv)

The employer shall document each inspection and test that has been performed on process

equipment. The documentation shall identify the date of the inspection or test, the name of the

person who performed the inspection or test, the serial number or other identifier of the equipment

on which the inspection or test was performed, a description of the inspection or test performed,

and the results of the inspection or test.

(5)

Equipment deficiencies. The employer shall correct deficiencies in equipment that are outside acceptable

limits (defined by the process safety information in paragraph (d)) before further use or in a safe and timely

manner when necessary means are taken to assure safe operation.

(6)

Quality assurance.

(i)

In the construction of new plants and equipment, the employer shall assure that equipment as it is

fabricated is suitable for the process application for which they will be used.

(ii)

Appropriate checks and inspections shall be performed to assure that equipment is installed

properly and consistent with design specifications and the manufacturer's instructions.

(iii)

The employer shall assure that maintenance materials, spare parts and equipment are suitable for

the process application for which they will be used.

Intent

The purpose of the mechanical integrity element is to ensure the integrity and safe operation of

process equipment through inspection, testing, preventative maintenance, and quality assurance.

The preventative maintenance program must be proactive rather than reactive, encompassing all

equipment used to process, store, or handle HHCs from installation through retirement.