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FACTSHEET
MECHANICAL INTEGRITY FOR PLANT CONTAINING HAZARDOUS SUBSTANCES Demonstrating Best Practice
EPM Solutions are one of the UK’s leading Engineering Asset Management specialists. Our clients mainly operate in industrial and hazardous environments, which is why we have created this useful factsheet to assist with best practice in mechanical integrity.
THE MECHANICAL INTEGRITY OF PLANT CONTAINING HAZARDOUS SUBSTANCES – A GUIDE TO PERIODIC EXAMINATION AND TESTING
MECHANICAL INTEGRITY
EEMUA PUBLICATION 231 - ED 1, SAFED PUBLICATION IMG 1
This factsheet considers the EEMUA guidance document 231 which covers all onshore equipment that provides the primary containment boundary to hazardous substances such as pressure vessels, relief streams, atmospheric storage tanks and pipework.
WE CAN HELP At EPM we work with a number of clients to help ensure they remain safe and can demonstrate best practice and compliance.
IF YOU ARE CONCERNED ABOUT AGEING PLANT ON YOUR SITE AND ARE LOOKING FOR MORE INFORMATION, EPM CAN HELP.
It covers plant such as pumps, agitators, valves and compressors in so far as they are required to maintain primary containment. It does not cover the maintenance of such plant necessary to ensure their continued operation. You can download the complete document online here http://bit.ly/Yr1yD0 or visit www.eemua.co.uk.
A range of plant and equipment is used in chemical plants, factories and depots for the storage, transfer and processing of hazardous substances. The mechanical integrity of vessels, pipework and other items of equipment containing these substances is the primary barrier against a loss of containment, and the potential realisation of inherent hazards those materials possess.
This is achieved by assessing existing documentation, systems and practices, then developing and implementing a written inspection program that is appropriate for the plants complexity and expected rate of deterioration.
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AGEING PLANT Ageing plant does not necessarily relate to chronological age. There are many examples of very old plant remaining fully fit for purpose, and of recently installed plant showing evidence of early ageing. When you think of ageing plant you would be forgiven for thinking of equipment that is either old or getting old. However, ageing is not about how old your equipment is; it is about its condition, and how that is changing over time. Ageing is the effect whereby a component suffers some form of material deterioration and damage (usually, but not necessarily, associated with time in service) with an increasing likelihood of failure over the lifetime. The significance of deterioration and damage relates to the potential effect on the equipment’s functionality, availability, reliability and safety. All types of equipment can be susceptible to ageing mechanisms.
RELEVANT LEGISLATION If you follow the guidance set out in EEMUA 231 you will normally be doing enough to comply with health and safety law such as: • Management of Health and Safety at Work Regulations (MHSWR) • Provision and Use of Work Equipment Regulations 1998 (PUWER) • Pressure Systems Safety Regulations 2000 (PSSR) • Control of Major Accident Hazards Regulations 1999 [as amended] (COMAH) • Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) • Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) • The Pollution Prevention and Control Regulations, 2000 These regulations ensure that businesses take all necessary measures to prevent major accidents involving dangerous substances. In addition, compliant businesses will limit the consequences to people and the environment of any major accidents that do occur.
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WHAT ARE HAZARDOUS SUBSTANCES? Hazardous substances are those with the potential to cause harm (either to people and/or the environment) as a result of their toxicity, flammability or other form of chemical reactivity (including explosives). If you handle, process and store such dangerous substances then this factsheet is ideal for you. For clarification you should refer to the dangerous substances listed in the Control of Major Accident Hazards (COMAH) Regulations.
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OVERVIEW OF INTEGRITY MANAGEMENT THROUGHOUT THE PLANT LIFECYCLE Successful management of plant integrity requires a clear strategy; not just for periodic examination, but for the whole plant lifecycle. This is especially important on sites storing and processing hazardous substances, where the consequences of integrity failure can be major.
CONSTRUCTION The physical construction needs to meet the detailed design intent, and there needs to be means to ensure this. The construction may be in a fabrication shop or built out on site, which may present different issues to be overcome.
WRITTEN SCHEME OF EXAMINATION (WSE) A WSE is a cornerstone of an examination regime, whether or not PSSR applies. It specifies the minimum examination and testing that will be carried out, how often, and any techniques that may be required. Before this can be developed, it is necessary to consider how the asset can degrade over time, and which techniques can detect this.
SPECIFICATION
DESIGN
Getting the original plant specification correct is key, so that plant is designed to be suitable for the intended duty. Some of the issues that need to be addressed include: size of the vessel / storage tank, contents of vessel, hazards of the substance, affect of the vessel by the contents and the required life span.
This is where the specification is translated into a physical detailed design that is fit for the intended duty. Up to this point the design has been more of a concept, but now it will take shape. The designer should consider matters such as selection of appropriate design code, what materials will be used for construction, and how do they impact inspection?
COMMISSIONING / RE-COMMISSIONING
PLANNED / REACTIVE MAINTENANCE TASKS / MAINTENANCE HISTORY
It is essential to ensure that all equipment is working correctly before starting the process. It is during start-up that a plant can see some of the most extreme transient operating conditions, before settling into steady state conditions.
MODIFICATION There may be times during the life of the plant when it needs to be modified. The driver for this may be a desired process change, or in response to revised best practice or regulation for that industry. Whatever the driver, it is important that the modification is subject to ‘management of change’ procedures, including appropriate risk assessments.
Routine ‘Planned Preventative Maintenance’ tasks are primarily designed to ensure the ongoing availability of the asset. These will include ‘servicing’ and operator routine check sheets that form the lowest level of inspection.
EPM PROVIDES A RANGE OF CONSULTANCY SERVICES FOR CLIENTS IN HAZARDOUS ENVIRONMENTS. TO DISCUSS YOUR INTEGRITY MANAGEMENT ISSUES CALL EPM ON 0141 848 6609
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OVERVIEW & CHECKLIST OF ISSUES TO CONSIDER IN A WRITTEN SCHEME OF EXAMINATION The WSE shall be prepared for each particular Hazardous System – (whether or not it is a Pressure or Non Pressure System).
The WSE may also reference other documents which are then encompassed under the WSE package. (not exhaustive): • A marked up copy of the Piping and Instrument Diagram(s) to show the system boundaries.
The WSE essentially comprises a schedule that is specific to each system and defines the items in the system that are subject to inspection and the periods for inspection. Photographs may also be included to highlight particular issues referred to in the WSE.
• A marked up copy of the system layout, isometrics and pipe route showing: • Locations of flanges, supports, instruments and potential leak paths, • Tank/ Vessel drawings, • High level access and areas requiring special arrangements, • Copy of Material Safety Data Sheet, • Design Codes, Specifications and limits, (inc torque)
When considering what should be included in the WSE the following subjects will help to provide a structure: • Nature of examination • Preparation • Anticipated degradation mechanisms • Examination methods
• Materials of construction, • Operating Parameters, • CMMS History – PM Schedules, Defect Reports, • Asset Register, • Maintenance and defect history, • Inspection reports, • FMEA and RBI reports.
• Identification • Relief stream • Photos • References • Design data • Operating data • Material of construction • Pressure test • Dates • Frequency
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FOR MORE INFORMATION OR TO DISCUSS MECHANICAL INTEGRITY IN HAZARDOUS ENVIRONMENTS CALL EPM ON 0141 848 6609