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Revision 0a, 03/20/09

VI. - MECHANICAL INTEGRITY PROGRAM Nevada Division of Environmental Protection

Chemical Accident Prevention Program

Data Form

1

1. Is there a Mechanical Integrity Program Procedure?

Title: Revision & Date:

2. Describe how all equipment, piping and instrumentation has been identified and evaluated to ensure necessary preventive maintenance as defined by vendors, plant experience or good engineering practice is being performed.

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Chemical Accident Prevention ProgramElement Audit Checklist


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3. Types of preventive maintenance identified. Check any that apply.

Type of Preventive Maintenance

C o r r o s i o n / E r o s i o n

M o n i t o r i n g

n o t e 1

O t h e r M o n

i t o r i n g

n o t e 2

C a l i b r a t i o n

F u n c t i o n T

e s t i n g

P a r t R e p l a c e m e n t

o r R e b u i l d

T o t a l R e p l a c e m e n t

O t h e r n o t e 3

Heat Exchangers

Other Types of Pressure Vessels & Storage Tanks

Piping Systems

Manual Valves

Pressure Relief Devices

Pressure Relief Systems (pressure relief discharge headers and flare

systems)

Scrubber Systems

Building Ventilation Systems (if CAPP process inside)

Emergency Shutdown Systems

Instrumentation

Sensors (toxic/combustible gas, flame)

Alarm Systems

Pumps

Compressors

Other Rotating Equipment

Notes:

1. Indicates corrosion or erosion monitoring through non-destructive examination, corrosioncoupons or other methods.

2. Indicates other types of monitoring such as external and internal visual inspection, vibration

monitoring or other types of monitoring.3.

Indicates other types of PM such as heat exchanger cleaning, valve rebuilding

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Questions to consider while developing the PM list and schedule (response to these questions on this form is not

required):

a. Is wall thickness monitored for all pressure vessels and storage tanks (operating in excess of 15 psi), and does

the frequency of monitoring consider historical wall loss or the potential for corrosion or erosion in the system?

b. Is wall thickness monitored for all vessels and storage tanks (operating at 15 psi or less), and does the frequency

of monitoring consider historical wall loss or the potential for corrosion or erosion in the system?

c. Is wall thickness monitored for all process piping (where failure could result in the release of toxic gas, or a fire

or explosion) and does the frequency of monitoring consider historical wall loss or the potential for corrosion orerosion in the system?

d. Are all pressure relief devices recertified or changed-out on a periodic basis, which includes verifying the set

pressure, and is the recertification conducted by a nationally recognized code shop when required?

e. Is the recertification of the pressure relief device pursuant to nationally recognized codes & standards, vendor

recommendations, industry recommendations or operating experience?

f. Are flares & igniters maintained in a manner and frequency consistent with vendor recommendations or

industry recommendations or operating experience?

g. Have scrubber components been evaluated for inspection type and frequency, and are the components being

maintained adequately? If the scrubber vendor recommends more stringent maintenance activities or schedule,

is this being maintained?

h. Are emergency shutdown system circuits checked for continuity, and are system components checked foroperability on some frequency? Are system components maintained pursuant to vendor recommendations,

industry recommendations or on a frequency and criteria based upon operating experience?

i. Are critical process instruments, controls and analyzers calibrated and maintained pursuant to vendor

recommendations, industry recommendations or on a frequency and criteria based upon operating experience?

j. Are pumps, compressors, blowers and other rotating equipment maintained pursuant to vendor

recommendations, industry recommendations, or on a frequency and criteria based upon operating experience?

NOTE: If instrumentation, sensors and alarms are used to initiate action under the Emergency Action

Plan / Emergency Response Plan, calibration and testing must be perform at least annually.

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4. Source of maintenance requirements and procedures. Check any that apply for each type of equipment or

instrumentation.

Source of Maintenance Procedures V e n d o r O & M

M a n u a l s

C o d e s &

S t a n d a r d s

I n d u s t r y

R e c o m m e n d e d

P r a c t i c e

F a c i l i t y

E x p e r i e n c e

O t h e r ( s p e c i f y )

Heat Exchangers

Other Types of Pressure Vessels & Storage Tanks

Piping Systems

Manual Valves

Pressure Relief Devices

Pressure Relief Systems (pressure relief discharge headers and flare

systems)

Scrubber Systems

Building Ventilation Systems (if CAPP process inside)

Emergency Shutdown Systems

Instrumentation

Sensors (toxic/combustible gas, flame)

Alarm Systems

Pumps

Compressors

Other Rotating Equipment

5. Is a work order system used to schedule and track preventive and corrective maintenance activities?

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6. Types of training provided to maintenance personnel. Check any that apply for each position listed below.

Type of Training(Below, list different maintenance positions including

mechanical, instrument & electrical) P r e v e n t i v e

M a i n t e n a n c e

P r o c e d u r e s

C o r r e c t i v e

M a i n t e n a n c e

P r o c e d u r e s

S a f e W o r k

P r a c t i c e s

O v e r v i e w o f

P r o c e s s

M a n a g e m e n t o f

C h a n g e

O t h e r ( s p e c i f y )

7. What system is in place to ensure the compatibility of new components and spare parts with the process?

8. What system is in place to ensure that equipment, instrumentation and electrical components are installed per designspecifications and vendor requirements?

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9. QA/QC (Quality Assurance / Quality Control)

Quality Assurance is the management oversight function of the portion of the Mechanical Integrity Program procedure

that deals with the proper specification, procurement, receiving, warehousing and installation of process components

Quality Control is the technical function of the Mechanical Integrity Program that insures verification that the process

components were installed according to the Quality Assurance Program.

What system is in place to insure:

a. Proper materials are specified?

b. Specified materials are ordered?

c. Specified materials are received?

d. Specified materials are issued for installation?

e.

Specified materials were correctly installed?

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