Document No.
: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 1-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 2-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
SECTION-1 TABLE OF CONTENTS
Section Description Page No.
SECTION-1 TABLE OF CONTENTS ....................................................................................................... 2
SECTION-2 PRINCIPLE ............................................................................................................................. 3
SECTION-3 ESSENTIAL FEATURES ....................................................................................................... 3
3.1 INSPECTION OR TEST DESIGN ...................................................................................................................................................... 3
3.2 GENERAL REQUIREMENTS .............................................................................................................................................................. 4
3.2.1 Applicable performance limits .................................................................................................................................. 5
3.2.2 Exception lists .............................................................................................................................................................. 5
3.2.3 Documentation records ............................................................................................................................................ 5
3.2.4 Record-keeping systems ............................................................................................................................................ 5
3.3 PREDICTIVE AND PREVENTIVE MAINTENANCE............................................................................................................................ 6
3.3.1 Repairs............................................................................................................................................................................ 6
3.3.2 Equipment Specific Requirements ........................................................................................................................... 6
3.4 RELIABILITY ENGINEERING ANALYSIS ........................................................................................................................................... 7
3.4.1 Safety Critical Defeat Analysis ................................................................................................................................. 7
3.4.2 Reliability Incident Report (RIR) .............................................................................................................................. 8
3.5 QUALITY CONTROL (QC) PROCEDURES ................................................................................................................................... 8
3.6 MAINTENANCE (MECHANICAL AND I&E) PROCEDURES........................................................................................................... 8
3.7 TRAINING AND PERFORMANCE OF MAINTENANCE PERSONNEL............................................................................................. 8
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 3-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
SECTION-2 PRINCIPLE
CHDOC to Thar Power Project believes that a comprehensive Mechanical Integrity (MI) program
is necessary to ensure that the system integrity to contain the hazardous substances is maintained
from the time of initial installation and throughout the life of the facility. MI addresses such topics
as following:
1. Equipment tests and inspections - predictive and preventive maintenance.
2. Reliability engineering
3. Maintenance procedures
4. Quality control procedures
5. Training and performance of maintenance personnel
The predictive and preventive maintenance and reliability engineering are important to help
ensure reliable and incident-free operation. It also avoids actual root cause of the problem to
recur. Such programs help prevent premature failure and help ensure operability of the systems
for emergency control.
SECTION-3 ESSENTIAL FEATURES
3.1 Inspection or Test Design
A written or computer-based design or procedure for inspecting or testing each equipment piece
or system must be prepared in advance. It shall include:
1. The equipment or system identification.
2. Inspection or test frequency.
3. The inspection methods to be used, including measurement locations.
4. Codes and standards to be followed.
5. Acceptable limits.
6. A means for finding the design basis and previous history.
7. Any special safety considerations.
8. Instructions for those who are to prepare the equipment or system for inspection.
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 4-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
3.2 General Requirements
9. An equipment inspection program shall be established for safety critical equipment consisting
of inspections and tests to detect impending or minor failures and procedures to mitigate their
potential before they can develop into more serious failures.
10. However, site management may also consider listing other equipment, taking into
consideration;
Actual equipment replacement cost
Relationship to identified critical equipment, or
The cost of system / unit shutdown for the repair of unsuspected equipment failure.
11. The following essential features of the test and inspection program shall be included:
Application listing developed for the equipment and systems subject to tests and
inspections.
Documentation of test objectives and method
12. Inspection and testing procedures shall follow Recognized & Generally Accepted Good
Engineering Practices (RAGAGEP).
13. Applicable codes and standards shall provide guidance in determining good engineering
practices.
14. 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 indicated by prior operating experience.
15. Sites shall document inspection and testing procedures with appropriate references to
applicable codes, standards and vendors’ recommendations that were used as a basis for good
engineering practices.
16. Variances from or substitutions for codes, standards, and recommended practices shall be
documented, including the reason for variance or substitution and a description of the
engineering practice used.
17. Integrity check (e.g. pressure test, thickness measurement, RT, NDT) of process equipment
shall be done at time of handover from mechanical to operations personnel, but prior to
acceptance.
18. Accuracy of testing and monitoring equipment used in the inspection process shall also be
verified.
19. All equipment testing shall be recorded and maintained. Instrument / interlock devices shall be
tested from the primary sensor down to the final trip element connected to the process. All
relays and control devices involved in the trip or alarm shall be exercised.
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 5-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
20. If a safety critical device, interlock or equipment can't be handed over for preventive
maintenance or dummy checkup (either one) HSE Committee waiver shall be obtained by the
owner of the equipment.
21. Site management and supervision shall analyze results to verify integrity.
22. Condition of equipment and recommendations for repairs or replacement shall be
documented and effectively communicated to the appropriate management. The results of the
program shall be reviewed periodically by HSE Committee.
23. Accepted recommendations shall be tracked until maintenance is complete.
24. Rationale for rejected recommendations or deferred maintenance shall be documented.
3.2.1 Applicable performance limits
Performance limits shall be established that are consistent with limits established in process
technology e.g. brittle fracture, hydrogen attack etc.
3.2.2 Exception lists
Exceptions lists shall be issued for corrective action and follow-up.
3.2.3 Documentation records
Documentation records shall be prepared showing that each inspection and test has been
performed in accordance with this section. The documentation shall identify the following
information:
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.
Results of inspection or test, including whether a pass or fail condition.
Recommended corrective action(s).
3.2.4 Record-keeping systems
1. Record-keeping system shall be developed to document test results in a way that facilitates
review and analysis of test data.
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 6-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
3.3 Predictive and Preventive Maintenance
1. A predictive/preventive maintenance program shall be established for all safety critical
equipment.
2. The following essential features of the Predictive & Preventive Maintenance shall be included:
A clearly defined and approved list should be developed for all equipment, which falls
under both programs.
3.3.1 Repairs
A repair and change program shall be established so that deficiencies are properly corrected and
that changes are done in a way that allow safe operation.
“Repair” is the returning of a deteriorated equipment piece or its setting to its original design
condition. It also includes replacement-in-kind. “Changes” take the equipment piece or its settings
to a design different from the previous design. “Temporary Repairs”, such as leak repair kits and
fillet-welded vessel patches, are usually “changes”.
All repairs and changes must follow Recognized and Generally Accepted Good Engineering
Practices (RAGAGEP).
Documentation of work shall be adequate to allow a sound Reliability Engineering program and be
kept in the equipment file or other system file as appropriate (also in reliability engineering
analysis).
3.3.2 Equipment Specific Requirements
In addition to general requirements given in section 3.2, site shall establish particular requirements
for following category of equipment:
1. Pressure vessels and tanks (including storage).
2. Pressure relief and vent systems and devices (including vent headers and flame arrestors).
3. Safety Critical devices:
Controls, interlocks, alarms, instruments and sensors classified safety critical.
Emergency devices, including shutdown systems and isolation systems.
Fire protection systems and equipment.
Emergency alarm/communication systems.
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 7-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
4. Piping systems (including piping components, such as valves, hoses and expansion
bellows/joints. Also the underground piping).
5. Key process-to-service tie-ins.
6. Electrical grounding and bonding.
7. Monitoring devices and sensors.
8. Pumps
9. Any other equipment containing hazardous materials or whose failure could lead to release of
hazardous materials
10. Any other systems that could impair mitigation of effects of hazardous materials if released.
3.4 Reliability Engineering Analysis
An ongoing reliability engineering analysis shall be conducted for equipment critical to process
safety. Reliability engineering is the process of evaluating how long a system and its individual
components can be operated safely before they are taken out of service for maintenance or
replacement. Such analysis enables continuous improvement of process safety performance,
complements a predictive/preventive mode of operation and should include the following basic
elements:
Identification of safety critical equipment.
System established to collect actual operating and equipment history data for critical
equipment.
Data organized to facilitate review.
Data readily available to personnel involved in planning future maintenance.
Data regularly reviewed and analyzed to identify potential problems or trends that call for
corrective action.
Corrective action taken.
The Site should make appropriate use of consultants when problems are encountered or share
experience and network with Sites with similar operation to maintain and enhance mechanical
integrity.
3.4.1 Safety Critical Defeat Analysis
Key aspect of carrying out a safety critical defeats analysis is to identify the problematic securities
which need frequent defeats.
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 8-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
The classification of problems is:
Preventive Maintenance to comply reliability plan for preventive maintenance / testing
purposes.
Avoid Nuisance Tripping to avoid nuisance tripping due to some heavy mechanical activity
in vicinity of the device components (sensors, JBs, tubing's, final trip elements).
Condition Based Repair Calibration and maintenance of primary sensing element, leakage
removal from tubing's, final trip elements etc. other than planned reliability plan.
Startup & Shutdown Load operation during startups and shutdowns
Any other Reasons Calibration of any other device having same tapping with the safety
critical device or any other reason apart reasons mentioned above.
11. Site management shall devise a system to carryout the defeat analysis of safety critical devices,
interlocks etc.
12. Defeat analysis shall be carried out at defined frequencies, the time interval between two
safety critical defeat analysis shall not be more than 02 years.
13. Defeat analysis shall be shared in Safe Operations Committee.
14. Recommendations of defeat analysis should be tracked and followed up till completion.
3.4.2 Reliability Incident Report (RIR)
The concerned area section head shall initiate an RIR to investigate the root cause of the 1 st time
and all the recurring problems.
3.5 Quality Control (QC) Procedures
QC procedures shall be established so that maintenance materials, spare parts and equipment
meet design specifications as delivered and to protect against inadvertent use of improper
materials. Positive Material Identification program would also be part of the procedure.
3.6 Maintenance (Mechanical and I&E) Procedures
Maintenance procedures shall be established and implemented to preserve the mechanical
integrity of process equipment on an ongoing basis.
3.7 Training and Performance of Maintenance Personnel
Document No.: CHDOC-
EEL-HSE/PSM/SP-20-01
Revision No. : Oct 2019
Process Safety Management Standard Mechanical Integrity Issue No. : 01
Level-1 Procedures Revision due : Nov 2022
Page No. : 9-9
CHDOC Thar Power Project Orig. Prepared by: HNM
Department: HSE Unit / Section: Safety Area : All
Maintenance personnel shall be trained consistent with the principles and essential features of the
personnel training and performance element. Training shall address an overview of the process,
specific safety and health hazards associated with the process, emergency procedures and work
practices applicable to specific tasks. The requirement given in the PSM on training would also be
applicable.
