Corresponding DOE Programs and Requirements

DOE-HDBK-1101-96

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 over-

flow 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 420.1,

FACILITY SAFETY, and DOE O 430.1, LIFE CYCLE ASSET MANAGEMENT which address

most requirements of the Mechanical Integrity element with little modification. DOE's quality

assurance program described in DOE 5700.6C helps to ensure that process equipment meets

specifications and is properly installed. Configuration control and management requirements found

in DOE O 430.1 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 appli-

cable 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 con-

tain:

written maintenance procedures [Q75,Q76];

inspection and test procedures;

trained process maintenance personnel;