4 mechanical integrity

7/27/2019 4 Mechanical Integrity

1/34

Preventing Chemical AccidentsPreventing Chemical AccidentsPreventing Chemical AccidentsPreventing Chemical Accidents

Mechanical IntegrityMechanical IntegrityMechanical IntegrityMechanical Integrity Preventing Maintenance BreakdownsPreventing Maintenance BreakdownsPreventing Maintenance BreakdownsPreventing Maintenance Breakdowns

Process Safety Management TrainingProcess Safety Management TrainingProcess Safety Management TrainingProcess Safety Management Trainingfrom thefrom thefrom thefrom the

NJ ork !nvironment Co"ncilNJ ork !nvironment Co"ncilNJ ork !nvironment Co"ncilNJ ork !nvironment Co"ncil

This material was #rod"ced "nder grant S$%&'(&)%*(%+*%,%)- from the .cc"#ational Safety and $ealth Administration/ 01S12e#artment of 3a4or1 It does not necessarily reflect the views or #olicies of the 01S1 2e#artment of 3a4or/ nor does mentionof trade names/ commercial #rod"cts/ or organi5ations im#ly endorsement 4y the 01S1 6overnment1 This c"rric"l"m is revisedfrom materials originally develo#ed 4y the 0nited Steelworker7s Tony Ma55occhi Center for Safety/ $ealth/ and!nvironmental !d"cation and #rod"ced 4y the Steelworkers Charita4le and !d"cational .rgani5ation/ f"nded in whole or in#art with f"nds from the .cc"#ational Safety and $ealth Administration/ 01S1 2e#artment of 3a4or 8grant n"m4er S$%&++)9%*'%+*%,%-9:1


2/34

2


3/34

Preventing Chemical Accidents; Mechanical Integrity Preventing Maintenance Breakdowns

i

Ta4le of ContentsTa4le of ContentsTa4le of ContentsTa4le of Contents

A4o"t !CA4o"t !CA4o"t !CA4o"t !C iiiiiiiiiiiiPreventing Chemical AccidentsPreventing Chemical AccidentsPreventing Chemical AccidentsPreventing Chemical Accidents ivivivivThe SmaThe SmaThe SmaThe Small 6ro"# Activity Methodll 6ro"# Activity Methodll 6ro"# Activity Methodll 6ro"# Activity Method vvvvTheTheTheThe ,actsheet


4/34


ii

A4o"t !CA4o"t !CA4o"t !CA4o"t !C

The New Jersey ork !nvironment Co"ncil 8!C: is a non%#rofit colla4oration oforgani5ations working for safe/ sec"re >o4s/ and a healthy/ s"staina4le environment1

?isit !C7s we4site at www1n>wec1org

,or more information a4o"t !C7s #rograms and services/ contact;,or more information a4o"t !C7s #rograms and services/ contact;,or more information a4o"t !C7s #rograms and services/ contact;,or more information a4o"t !C7s #rograms and services/ contact;


5/34


iii

Preventing Chemical AccidentsPreventing Chemical AccidentsPreventing Chemical AccidentsPreventing Chemical Accidents

0ne#ected rel0ne#ected rel0ne#ected rel0ne#ected releaseseaseseaseseases of highly ha5ardo"s toic/ reactive/ or flamma4le chemicalscreate the #ossi4ility of a disaster for workers/ em#loyers/ and comm"nities1

.S$A7s Process Safety Management Standard.S$A7s Process Safety Management Standard.S$A7s Process Safety Management Standard.S$A7s Process Safety Management Standard hel#s #revent accidental releases ofhighly ha5ardo"s chemicals/ th"s #rotecting em#loyees/ as well as #lant neigh4ors1

!ffective worker training!ffective worker training!ffective worker training!ffective worker training a4o"t PSM hel#s achieve safer/ healthier/ and more#rod"ctive work#laces1

In New Jersey/ PSM reg"lates a##roimately &** facilities/ incl"ding certainchemical #lants/ oil refineries/ food #rocessors/ electric "tilities/ wareho"ses/ and#"4lic and #rivate sector water and sewage treatment o#erations1 PSM may alsocover other ty#es of facilities1 PSM has s#ecial #rovisions for contractors working incovered facilities1

!C7s tra!C7s tra!C7s tra!C7s training c"rric"l"mining c"rric"l"mining c"rric"l"mining c"rric"l"m covers key as#ects of the PSM standard1 Trainingintrod"ces the conce#t of systems of safety and accident #revention and whyfacilities sho"ld esta4lish an organi5ational str"ct"re to oversee PSMim#lementation1 e address .S$A7s #erformance%4ased re"irements for a #lant

Dmechanical integrityE #rogram1 Training also covers accident/ incident/ and near%miss investigations/ foc"sing on root ca"ses1 e also can #rovide training on closelyrelated s"4>ects/ s"ch as the New Jersey Toic Catastro#he Prevention Act 8TCPA:/em#loyer and workerF"nion rights to #artici#ate d"ring .S$A and TCPAins#ections/ and develo#ment of effective la4or%management safety and healthcommittees1

,or more information/ contact;,or more information/ contact;,or more information/ contact;,or more information/ contact;2enise Patel/ PSM ."treach Coordinator!C/ &-9 est State St/ Third ,loor

Trenton/ NJ *(+*(

.r call; 8+*@: +@=%'&**/ !tension )*=,a; 8+*@: +@=%'&**!%Mail; d#ateln>wec1org


6/34


iv

The Small 6ro"# Activity MethodThe Small 6ro"# Activity MethodThe Small 6ro"# Activity MethodThe Small 6ro"# Activity Method

Basic Str"ct"reBasic Str"ct"reBasic Str"ct"reBasic Str"ct"reThe Small 6ro"# Activity MethodG is 4ased on a series of #ro4lem%solving activities1An activity can take from -= min"tes to an ho"r1 !ach activity has a common 4asicstr"ct"re;

H Small 6ro"# TasksSmall 6ro"# TasksSmall 6ro"# TasksSmall 6ro"# TasksH


7/34


v

Three Basic 3earning !changesThree Basic 3earning !changesThree Basic 3earning !changesThree Basic 3earning !changesThe Small 6ro"# Activity Method 8S6AM: is 4ased on the idea that every training is

a #lace where learning is shared1 ith S6AM/ learning is not a one%way street thatr"ns from trainer to worker1


8/34


vi

The ,actsheet


9/34


1

Mechanical IntegrityMechanical IntegrityMechanical IntegrityMechanical Integrity %%%%Preventing Maintenance BreakdownsPreventing Maintenance BreakdownsPreventing Maintenance BreakdownsPreventing Maintenance Breakdowns

P"r#oseP"r#oseP"r#oseP"r#osessss

To 4ecome familiar with the .S$A #erformance%4ased re"irements for a #lantDmechanical integrityE #rogram1

To eamine the ca"ses and sol"tions of D4reakdownE maintenance1

This Activity has two tasks1


10/34


2

Task &Task &Task &Task &

In yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheetsIn yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheetsIn yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheetsIn yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheets &&&& %%%% + on #ages )+ on #ages )+ on #ages )+ on #ages ) %%%% &&&&&&&&/ answer/ answer/ answer/ answerthe following "estionthe following "estionthe following "estionthe following "estionssss;;;;

&1 hat are some ca"ses of maintenance 4reakdownsL&1 hat are some ca"ses of maintenance 4reakdownsL&1 hat are some ca"ses of maintenance 4reakdownsL&1 hat are some ca"ses of maintenance 4reakdownsL

91 Co"ld maintenance 4reakdowns ha##en at yo"r #lantL 3ist some eam#les191 Co"ld maintenance 4reakdowns ha##en at yo"r #lantL 3ist some eam#les191 Co"ld maintenance 4reakdowns ha##en at yo"r #lantL 3ist some eam#les191 Co"ld maintenance 4reakdowns ha##en at yo"r #lantL 3ist some eam#les1


11/34


3

,actsheet &,actsheet &,actsheet &,actsheet &

Maintenance Myths Most .ften $eardMaintenance Myths Most .ften $eardMaintenance Myths Most .ften $eardMaintenance Myths Most .ften $eard

$ere are some commonly%"sed ec"ses for not following safe mechanical integrity#ractices and eam#les of the conse"ences of not doing so;

It7s only tem#orary;It7s only tem#orary;It7s only tem#orary;It7s only tem#orary;A leak develo#ed on one of the si in%line reactors1 All si were connected with 9(%inch%diameter #i#es and e#ansion 4ellows1 The leaking reactor was 4y#assed witha 9*%inch #i#e with two el4ows and the e#ansion 4ellows were left intact1

The #i#e was not s"##orted #ro#erlyK it was resting on scaffolding1 Beca"se of the4ellows/ it was free to rotate or Ds"irmE and in the #rocess it failed/ killing 9(#eo#le and destroying the #lant1

It7s factory setK no need to test it;It7s factory setK no need to test it;It7s factory setK no need to test it;It7s factory setK no need to test it;In an a"tomatic fire%fighting system/ a small e#losive charge c"t a r"#t"re disc andreleased the fire%fighting agent/ $alon1 The man"fact"rer said it was not necessaryto test1 To test wo"ld re"ire the loss of the $alon which was very e#ensive1

The 4"yer insisted on the test even with the added e#ense1 The smoke detectorsworked 4"t when the e#losive charge was activated/ the r"#t"re disc was notactivated1 The man"fact"rer was in error1


12/34


4

,actsheet & 8contin"ed:,actsheet & 8contin"ed:,actsheet & 8contin"ed:,actsheet & 8contin"ed:

6o ahead and "se this oneK it7ll work;6o ahead and "se this oneK it7ll work;6o ahead and "se this oneK it7ll work;6o ahead and "se this oneK it7ll work;A car4on steel valve was #ainted with al"min"m #aint instead of "sing a stainlesssteel valve1 It corroded ra#idly1

I don7t need an o#eratorK I7m >"st going to look;I don7t need an o#eratorK I7m >"st going to look;I don7t need an o#eratorK I7m >"st going to look;I don7t need an o#eratorK I7m >"st going to look;A maintenance foreman was asked to look at a fa"lty cooling water #"m#1 $edecided that/ to #revent damage to the machine/ it was essential to red"ce its s#eedimmediately1 $e did so/ 4"t did not tell any of the o#erators1 The cooling waterrate fellK the #rocess was "#setK and a leak develo#ed on a cooler1

So"rces; Accident at Amoco Chemicals related 4y 6lenn !rwin/ $ealth and Safety Coordinator/ .CA 8now 0S:Kand Trevor A1 let5/ hat ent rongL Case $istories of Process Plant 2isasters/$o"ston; 6"lf Coast P"4lishingCom#any/ Second !dition/ Novem4er &@(@1


13/34


5

,actsheet 9,actsheet 9,actsheet 9,actsheet 9

ork .rder Backlog; & arning Signork .rder Backlog; & arning Signork .rder Backlog; & arning Signork .rder Backlog; & arning Sign

Most com#anies have very good written #reventive maintenance 8PM: #lans one"i#ment1 B"t in reality/ as the work orders #ile "#/ they are "na4le to kee# theirPMs ca"ght "#1

To make matters worse/ #reventive maintenance work orders are often treated ashaving a lower #riority than most other work orders1

The #ro4lem is com#o"nded 4y the fact that most com#anies do not em#loyeno"gh maintenance workers to stay on to# of the reg"lar work orders/ m"ch lessthe PMs1

A h"ge 4acklog of work orders is a sign that the Mechanical Integrity 8MI: #rogramis not doing what it is intended to/ and it may 4e considered a violation of the#erformance%4ased Process Safety Management 8PSM: Standard1


14/34


6

,actsheet ),actsheet ),actsheet ),actsheet )

If It Ain7t Broke 1 1 1If It Ain7t Broke 1 1 1If It Ain7t Broke 1 1 1If It Ain7t Broke 1 1 1

Many com#anies conscio"sly decide to


15/34


16/34


8

,actsheet - 8contin"ed:,actsheet - 8contin"ed:,actsheet - 8contin"ed:,actsheet - 8contin"ed:

The #otential for disaster is #resent;The #otential for disaster is #resent;The #otential for disaster is #resent;The #otential for disaster is #resent;

D3eaks of all sorts; oil/ chemicals/ which incl"de tol"ene/ ketone/ etc1/ are notaddressed in a timely manner1 The limited amo"nt of maintenance #eo#le are ke#t4"sy doing work necessary to maintain #rod"ctionK and the less im#ortant#ro4lems/ in the com#any7s >"dgment/ are left "nattended1E

0nderstaffing leads to ecess overtime and fatig"e;0nderstaffing leads to ecess overtime and fatig"e;0nderstaffing leads to ecess overtime and fatig"e;0nderstaffing leads to ecess overtime and fatig"e;

ears after this &@@& testimony/ the #ro4lem of "nderstaffing and related etended

working ho"rs was highlighted 4y the 01S1 Chemical Safety and $a5ardInvestigation Board 8CSB: in their 9**' Investigation


17/34


18/34


10

,actsheet = 8contin"ed:,actsheet = 8contin"ed:,actsheet = 8contin"ed:,actsheet = 8contin"ed:

A )*%year st"dy of accidents in the #etrochemical ind"stry revealed that incidentswhich res"lted in Dlarge #ro#erty damage lossesE were most often ca"sed 4ymechanical fail"re in the #rocess e"i#ment 8-& #ercentof the time:1 The most recent "#date of this st"dy shows #i#ing fail"res and leaks/cryogenic #lant e"i#ment fail"re/ and weather conditions as ma>or ca"ses1

So"rces; 01S1 2e#artment of Commerce/ S"rvey of C"rrent B"siness/ J"ne iss"esK 6arrison/ 1 !1/ P!/ 3arge Pro#erty2amage 3osses in the $ydrocar4on%Chemical Ind"stries; A Thirty%ear


19/34


11

,actsheet +,actsheet +,actsheet +,actsheet +

3onger Time 4etween T"rnaro"3onger Time 4etween T"rnaro"3onger Time 4etween T"rnaro"3onger Time 4etween T"rnaro"nds 3eads to 2angernds 3eads to 2angernds 3eads to 2angernds 3eads to 2anger

Prior to the &@'*s/ the average length of time 4etween t"rnaro"nds was one year1Now this #eriod is m"ch greater/ with the d"ration 4etween t"rnaro"nds sometimesas long as five years1 This longer length of time means that some e"i#ment/ whichcan only 4e re#aired when the "nit is sh"tdown/ has to wait1

A ty#ical res"lt of long t"rnaro"nd times is that #rocess "nits are r"n "nderdangero"s conditions that wo"ld not have 4een acce#ta4le years ago1 A tr"e life

eam#le is told in the Dcalc"lated risksE story 4elow;

The Calc"lated oint so the o#erator co"ldmonitor the hole1 The "nit sho"ld have 4een sh"t down1 It wo"ld have 4eensh"t down ten years agoK however/ a decision was made to contin"e r"nningthe "nit des#ite the #otential of very radical conse"ences1E

So"rce; 0S mem4er Jimmy $errington/ 3ocal -%9-)/ testimony 4efore .S$A/ ,e4r"ary 9-/ &@@&1


20/34


12


21/34


13

Task 9Task 9Task 9Task 9

Scenario;Scenario;Scenario;Scenario;

2"ring the night shift on "nit DAE at ChemPetro/ the #rocess o#erator/ 2e44ie/noticed a severe vi4ration on !%&*& D6E fan1 She radioed the control room andasked the Board .#erator/ Jim/ to write a work order to get the 4earings re#laced1

Jim filled o"t the work order and gave it to his ,oreman/ Bo41

Bo4 made a notation in the "nit log 4ook that the 4earings were 4ad and forwardedthe work order to the "nit s"#ervisor for a##roval1 Bo4 and his crew were finishing

"# their night rotation and were starting their days off1

hen !rnest/ the 0nit S"#ervisor/ arrived on the day shift/ he assigned it a #riorityD9E 8com#lete within a week: 4eca"se it was cool o"tside and he knew they co"ldr"n witho"t it1 Besides/ the maintenance crew was already 4"sy re#airing thecentrif"ge which was a #riority D&E 8overtime a"thori5ed:1

At );** a1m1 on the following day/ the 4earing failed on !%&*& D6E creating s"ch avi4ration that a #ress"re ga"ge leaked/ ca"sing a fire1

2"ring the investigation that followed/ it was fo"nd the vi4ration switch had failedto tri# the fan off the line1 It had 4een wired wrong/ #ro4a4ly since the time ofinstallation1


22/34


14

TaskTaskTaskTask 9999 8contin"ed:8contin"ed:8contin"ed:8contin"ed:

In yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheetsIn yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheetsIn yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheetsIn yo"r gro"#s/ choose a scri4e1 Then/ "sing factsheets &&&& %%%% + on #ages+ on #ages+ on #ages+ on #ages &-&-&-&- %%%% 9999&&&&////answer the following "estionanswer the following "estionanswer the following "estionanswer the following "estionssss;;;;

&1 3ist ways this fire co"ld have 4een #revented1&1 3ist ways this fire co"ld have 4een #revented1&1 3ist ways this fire co"ld have 4een #revented1&1 3ist ways this fire co"ld have 4een #revented1

91919191 In yo"r gro"#s/ dIn yo"r gro"#s/ dIn yo"r gro"#s/ dIn yo"r gro"#s/ develo# a D#reventive maintenanceE #rogram for ChemPetro1evelo# a D#reventive maintenanceE #rogram for ChemPetro1evelo# a D#reventive maintenanceE #rogram for ChemPetro1evelo# a D#reventive maintenanceE #rogram for ChemPetro13ist the key elements of the #rogram 4elow13ist the key elements of the #rogram 4elow13ist the key elements of the #rogram 4elow13ist the key elements of the #rogram 4elow1


23/34


15

,actsheet ,actsheet ,actsheet ,actsheet &&&&

The PSThe PSThe PSThe PSM Standard Is DPerformanceM Standard Is DPerformanceM Standard Is DPerformanceM Standard Is DPerformance%%%%4asedE4asedE4asedE4asedEA


24/34


16

,actsheet ,actsheet ,actsheet ,actsheet &&&& 8contin"ed:8contin"ed:8contin"ed:8contin"ed:

o" sho"ld ask yo"rself the following "estion when reviewing yo"ro" sho"ld ask yo"rself the following "estion when reviewing yo"ro" sho"ld ask yo"rself the following "estion when reviewing yo"ro" sho"ld ask yo"rself the following "estion when reviewing yo"r facility7sfacility7sfacility7sfacility7s PSMPSMPSMPSM#rogram;#rogram;#rogram;#rogram;

ill this #rogram/ as it is written and a##lied/ hel# to #revent accidentsL Ifthe answer is Dno/E then the com#any is not com#lying with the s#irit andintent of the law1

,or eam#le/ if the com#any develo#s a #reventive maintenance #rogram8PM: 4"t assigns PM work orders low #riority/ yo"r work e#erience tells yo"that there really is no PM #rogram


25/34


17

,actsheet ,actsheet ,actsheet ,actsheet 9999

hat thehat thehat thehat the PSMPSMPSMPSM Standard CoversStandard CoversStandard CoversStandard Covers

The re"irements for mechanical integrity "nder the PSM Standard a##ly to sis#ecific ty#es of #rocess e"i#ment where fail"re is likely to 4e catastro#hic1

These ty#es of e"i#ment/ "sed in the handling of highly ha5ardo"s chemicals are;

&1 Press"re vessels and storage tanksK

91 Pi#ing systems 8incl"ding valves and other com#onents:K

)1


26/34


18

,actsheet ,actsheet ,actsheet ,actsheet ))))

.S$A7s !lements for an MI Program.S$A7s !lements for an MI Program.S$A7s !lements for an MI Program.S$A7s !lements for an MI Program

According to .S$A/ the necessary elements of a good mechanical integrity 8MI:#rogram are;

!sta4lish and im#lement written #roced"res to maintain the integrity of#rocess e"i#ment1

Train em#loyees and contractors involved in maintaining the integrity ofe"i#ment1

Perform #eriodic ins#ection and testing/ following Drecogni5ed and generallyacce#ted good engineering #ractices/E and doc"ment that ins#ections have4een done1

Correct e"i#ment deficiencies 4efore f"rther "se or in a safe and timelymanner1

2evelo# a "ality ass"rance #rogram to ens"re that;

o !"i#ment for new #lants is s"ita4le for "se in the #rocess/ and is#ro#erly installedK and

o All maintenance materials/ s#are #arts and e"i#ment are s"ita4le forintended "se1

So"rce; .S$A Process Safety Management Standard/ 9@ C,< &@&*1&&@/ =' ,< +)=+/ ,e4r"ary 9-/ &@@91


27/34


19

,actsheet ,actsheet ,actsheet ,actsheet ----

hy Preventive MaintenanceLhy Preventive MaintenanceLhy Preventive MaintenanceLhy Preventive MaintenanceL

It7s the 3awIt7s the 3awIt7s the 3awIt7s the 3aw

.S$A; The PSM standard re"ires #reventive maintenance 4e #erformed 4eforef"rther "se of the e"i#ment or in a safe and timely manner when necessary meansare taken to ass"re safe o#eration1

!PA; The !nvironmental Protection Agency has r"les to cover #reventive

maintenance #rograms within its "stification m"st 4e #rovided incl"ding an e#lanation of the necessary meas"restaken to ens"re safe o#eration1

TCPA also re"ires com#anies to maintain acc"rate records of all ins#ections/4reakdowns/ re#airs and re#lacements of #rocess e"i#ment1 All mechanicalintegrityF#reventive maintenance records m"st 4e ke#t for the lifetime of the#rocess e"i#ment1


28/34


29/34


21

,actsheet ,actsheet ,actsheet ,actsheet ====

NotNotNotNot All !m#loyees


30/34


22

This list ill"strates >"st a few eam#les of the h"man cost to 4oth workers and thecomm"nity ca"sed 4y fail"re to #ro#erly maintain #rocess e"i#ment1

Pi#ing; 8InternaPi#ing; 8InternaPi#ing; 8InternaPi#ing; 8Internal Corrosion of .verhead Pi#ing:l Corrosion of .verhead Pi#ing:l Corrosion of .verhead Pi#ing:l Corrosion of .verhead Pi#ing:May =/ &@(( U An e#losion and fire at a Shell .il


31/34


23

S"mmary; Mechanical IntegrityS"mmary; Mechanical IntegrityS"mmary; Mechanical IntegrityS"mmary; Mechanical Integrity

&1 Preventive maintenance #rograms sho"ld 4e esta4lished/ f"nded and staffed tos"fficient levels to avoid the need for D4reakdownE maintenance1

91 T"rnaro"nds need to 4e held often eno"gh to avoid D4reakdownEmaintenance1 0nits need to stay down "ntil sched"led re#airs are com#leted1

)1 All maintenance work sho"ld 4e #erformed 4y trained and e#eriencedcrafts workers1

-1


32/34


24


33/34


34/34


=1 $ow co"ld this activity 4e im#rovedL

Additional Comments;

4 mechanical integrity

Documents