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PROCESS SAFETY AND LOSS PREVENTION AUDIT
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C. Mechanical Integrity
Mechanical Integrity is a new term used in the OSHA Process Safety Management Regulation (1910.119, Paragraph J). At Dow, Mechanical Integrity includes the
items in this section:
Electrical Systems
Fire Protection Systems
Fired Equipment
Critical Instrument Systems
Emergency Block Valves
Storage Tanks
Pressure Vessels/Relief Devices/Glass Devices/Expansion Joints
Critical and Rotating Equipment (Including Compressors and Pumps)
Management Systems
Piping, Compressors and Pumps
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Mechanical Integrity
ELECTRICAL SYSTEMS
REFERENCES: Minimum Requirements, National Electric Code, LPP 3. Included as part of the Loss Prevention Audit, is an Electrical 5-Point inspection by the Electrical Maintenance Department. Contact your area electrical supervision to verify and coordinate this activity.
Following is a list of some Loss Prevention items that will be included in that plant's inspection:
1) . The Electrical Area Plot Plan drawing should be reviewed and current. Contact Loss Prevention if revisions are required. (L.P.P.)Identify any installations that are in conflict with electrical plot plan.
2) . The Safety Electrical One Line Diagram (SEOLD) should be reviewed and current per LAD S&LP S-214.
3) . The electrical field audit will be included an inspection of existing installations to observe mechanical integrity maintenance needs and conformance with L.P.P.-3., the National Electrical Code, and Area Classification practices.
4) . The results of this Electrical Department 5-Point inspection audit be included in the follow-up portions of this audit.
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_________________ _________________
Mechanical , " .'.'I''- Integrity
FIRE PROTECTION SYSTEMS
REFERENCES: Minimum Requirements
C 1. Yes 0^ No [] Do you have fire monitors and/or fixed sprinkler systems to protect flammable areas?
Plans:
_______________________________
B 2. Yes B7 No [] Do you have a plant program to routinely exercise/test fire monitors and fixed sprinkler systems?
Plans:
____________________
3. Yes 0^ No [] Is your extinguisher testing up-to-date and are thev in eood condition?
Plans:
B 4. Yes $ No [] Are the size and type of extinguishers
appropriate to the anticipated fire -- for example, a "C" rated extinguisher where electrical fires could be expected? Yes Gr No [] Are they properly located (i.e., office, MCC, switchgear rooms)?
Plans:
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B 5. Yes
No [] Have your employees participated in fire extinguisher training?
B 6. Yes [] No fj Do you have hose cabinets? Yes [] No [] If yes, are employees trained on their use? Yes [] No [] Is there a Preventative Maintenance Program on the hoses? Yes No [] Are the hose cabinets necessary?
C 7. Yes
No [] Do office areas, MCC's, switchgear, computer rooms and unoccupied buildings have smoke detectors alarming in a 24-hour/day occupied area? (LPP 9.1 and 9.2)
Plans:
A 8. Yes [j No [] Are checks of smoke detectors made routinely and documented? (LPP 10.13)
Plans:
C 9. How is your structural steel protected from a spill fire? (LPP 10.10)
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B 10.
Yes 0 No[] NA 0^
Is fire proofing well maintained? (LPP 10.10.7) Yes [] No [] /jf^tVj Is there an inspection program?
Date of Last Inspection? Plans: _____________
B 11.
Yes [] No [] NA[y^
Is pipe insulation on hot lines (i.e.:
150# steam or DOWTHERM*) in
good condition to prevent a
chemical leak from entering the
insulation and auto-igniting?
.
(LPP 10.12.4)
Plans: _________________________
A 12.
Yes No [] NA 0^
Are gas AND spill detectors adequately maintained (LPP 9.9.6) and tested routinely? (LPP 10.13) Provide Documentation.
Plans: ___________________________
B 13.
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Yes No Q/
Do you maintain foam within your area to fight fires? (LPP 5.8)
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If yes, what kind of foam is used and when was the material last tested?
Contact the Fire Department for the above information.
Plans:
Trademark of The Dow Chemiqal Company.
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B - DELUGE & SPRINKLER SYSTEMS
REFERENCE: Fire Protection Manual -- The intent of this page is to assure that
are properly maintained. Your process Safety and Loss Prevention contact can ass
out.
EXAMPL
:<:fX
Adequate access to valves during an
Yes
Explosion or traffic exposure to valve?
No
Explosion or traffic exposure to piping?
No
Is the valve freeze protected?
Yes
Is the system adequately drained of .... . - _o Is the pilot system adequately drained of
Yes Yes
Is remote dump switch labeled on deluge
Yes
Date of most recent 2" drain test?
1/18/85
Static pressure in recent drain test (psig)?
92
Flowing pressure in recent drain test
90
Design flow (gpm)?
2123
Design pressure at deluge valve inlet
11
Date of last flow test?
10/12/8
Were there plugged heads/corrected?
Yes/Yes
/
/
l
Are any pilot heads painted?
No
Is there any missing or damaged pipe?
No
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Use another page if you have more than six sys
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Mechanical Integrity
PRESSURE VESSELS/RELIEF DEVICES/GLASS DEVICES! EXPANSION JOINTS
REFERENCES: Minimum Requirements, LPP 6.5., 6.9.
A 1. Yes [] No Are all pressure vessels (Pressure Containing Equipment) registered?
If no, how many are not? _____ ____________________
7* 77 / /f
:
Yes [/
No [] Do you have any vendor-supplied
tanks in your plant?
(i.e,, the vendor fills)I a
4- L a r A vt a a # Fm lln 1
^
How do you assure mechanical integrity for these vessels?
-.-/-Y---/'f/irt------/^Y*<f-----/-7--f-Y.
B 2. Yes [] No [/Do file folder(s) on each pressure vessel (Pressure Containing Equipment) have the registration form, calculations, inspection and status change reports, spec sheets, record prints, U-l forms, mill tests, and visual inspections? (LPP 6.54.0
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B 3. Who is responsible for managing the pressure vessel testing inspection program in your plant? __________
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C 4. List any vessels with known mechanical integrity problems.
Plans:
Have current inspection printout on pressure vessel and relief valve status available at the audit.
B 5. Yes
No[] Has responsibility for execution of the
pressure relief devices (i.e., valves and
rupture discs, vacuum reliefs)
program been specifically assigned?
r 1 '
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A 6. Yes No[] Are all pressure relief devices registered? (LPP 14.3.4)
Plans: _______________________________________
A 7. Yes 0^ No [] Are design calculations on all pressure relief devices done?(Corporate Relief Design Manual)
If no, number incomplete? Schedule for completion?
B 8. Is there a file folder for each pressure relief device with registration form, design calculations, specifications and piping isometric sketch? Yes M No [] Plans:
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A 9. Yes [] No (yj Have all glass devices in hazardous
service been registered?
Plans:
St'si//r
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B 10.
Yes Not]
Are glass devices in hazardous service adequately guarded?
Plans:
B 11. Plans:
Vest/ No[]
Are required inspections, maintenance, evaluation and recordkeeping done for glass devices in hazardous service? (Site Safety Standards)
C 12. A 13.
Yes [v^ No []
Does the plant utilize expansion joints in hazardous applications? (Site Safety Standards)
Yes 0^ Non
Are all expansion joints registered? Plans: ___________________________________________
B 14.
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Plans:
Are required inspections, maintenance, evaluation and recordkeeping done?
B 15.
Yes No []
Plans:
Does your plant have a test/replacement program for flexible hoses?
/fC _______________________ __ 7" T
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M e c h ani ` s."' Integrity
CRITICAL AND ROTATING EQUIPMENT
These questions pertain primarily to large rotating equipment but also apply to equipment critical to the operation of the plant (hard to replace, costly).
REFERENCES: LPP 16.1.
A/C 1.
Yes NoD
Plans:
Have you identified your critical equipment? (Please attach your list.) (LPP 16.1.2)
R 2. Yes j/f No [] Does the list include items such as large
and/or unusual motors, transformers,
foreign and/or domestic equipment
Plans:
requiring long deliveries? (Centrifuges and Blowers)
B 3. Yes [if No [] Do you have adequate spare parts to
Plans:
minimize downtime (business interruption)?
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B 4. Yes 0^ No[] Are spares/spare parts stored in a
Plans!
controlled environment? ist///rC -/ /Vt;/S4/ /'///,
B 5. Yes [] No Do you have adequate
monitoring/protection devices for your
identified critical equipment? (LPP
Plans:
16.1.4)
T4 ft/////d///
r
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B 6. Yes 0^ No [] Do you have vibration monitors?
Plans:
^
Ss*^ s,^^
B 7. Yes No [] Do you have an on-going preventative
maintenance program? (LPP 16.1.5)
Please describe:
***,*/***&.
Plans:
^
8. Yes 0^No [] Do you have dead-head protection on
Describe: Plan?
all pumps?
(LPP 16.4.)
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1/
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B 9. Yes $ No [] Are stainless steel bolts a problem
because of potential process or
atmospheric corrosion?
If so, how do you control their use? A/? a4
J'yAr^/ciO jT/tL/*
_____________________________
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echan Integrity 'N"
MANAGEMENT SYSTEMS
REFERENCES: OSHA Process Safety Management (1910.119, Paragraph J)
7
A 1. Yes [] No [] Do you have written procedures to assure on-going integrity of process equipment? (i.e., pressure vessels, EBV's, fire protection systems, etc.)
Plans:
A 2. Yes 0 No [] Do you train each employee involved in maintaining the on-going integrity of process equipment in an overview of the process and its hazards and in the procedures applicable to the employees job task to assure that the employee can perform the job in a safe manner.
Plans: _________________________________________
A 3. Yes No [] Do inspection and testing procedures follow Dow site or Division guidelines?
Plans: _________________________________________
A 4. Yes 0^ No [] Do the frequency of inspections and
Plans:
tests of process equipment meet accepted Dow site or Division guidelines?
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5. Yes $ No [] Are all inspections and tests
documented as per Dow guidelines?
Plans: ______________________________
______,,
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A 6. Yes
No [] Are deficiencies discovered from tests and inspections corrected before further use or in a safe and timely manner when necessary means are taken to assure safe operations. Plans:
A 7. Yes No[] In the construction of new plants and equipment, is equipment fabricated according to Dow site or Division standards and suitable for the process application for which they will be used?
Plans: '
A 8. Yes $ No [] Are appropriate checks and inspections performed to assure that equipment is installed properly and consistently with design specifications and manufacturers instructions? Plans:
B 9. How do you assure that maintenance materials, spare parts and equipment are suitable for the process application for which they are being used?
/$***> Plans:
die
B 10.
How do you ensure the proper
materials of construction are used in maintenance
and new projects?
^ s^/y
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_________ _______________________ _
Plans:______ ___________________
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B 11.
Yesg7 No[]
Do you have a list of the proper gaskets
for each part of your process? (LPP
6.6)
Plans: ___________
Yes No [] Is gasketing covered in your piping specification?
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Mechanical Integrity
PIPING, PUMPS, COMPRESSORS
REFERENCES: Pipeline Technology Center (Angleton, TX), Dow Pipeline-Texas Operations only (Freeport, TX)
B
B B
A 4. Yes $ No [] Has definite ownership, including predictive, preventative maintenance (PPM) responsibilities, been clearly defined between the origin and termination of your pipelines?
B 5. Yes
No [] If more than one owner is involved for outside-block-limits pipelines, does each concur in writing with your interpretation of the extent of ownership?
B 6. Yes [] No $ Do you have records showing the
design criteria for each of your
pipelines (material of construction.
MAWP, operating pressure, costings, *
etc.)? ^ *4#'/
/*/*'*"* **??y*
Where is the information kept?
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ESSSSS5K3|^
B 7, Do you have a scheduled and documented periodic program for maintaining your pipelines for: Yes No [] N/A [] Painting? Yes if No [] N/A []
Cathodic Protection? Yes [/ No [] N/A []
Ground Interface Deterioration? N/A[] Surveillance?
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Nog^re your pipelines in the original B 8. Yes []
service for which they were designed? /Psj-//?/:/
/ /fi Cm/dr/Si'- fr, /srjt &//(* a4''`TTrfi,!, t
B 9. Yes [] No [j Do you maintain a record of pipeline repairs?
, Jss,
B 10.
Where are the repair records kept? __
B 11.
If another owner is responsible for
working on/repairing one of your outside-block-
limits pipelines, how do they know the hazards (if
any) associated with your materials?
____ txy/-
B 12.
Yes [] No[/ N/A []
B 13.
When work is performed by others on lines adjacent to yours, do you inspect the repair scene to assure the integrity of your piping has not been compromised?
Yes H7 NoQ N/A[]
Within the last 5 years, has your coated buried piping been free of leaks or other problems?
If "NO", what type (material) of coating was involved? __________________________
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B 14. B 15.
B 16.
B 17. B 18.
B 19. 4/1 1/94 Dow Confidential JFM:jl/27
Yes [] Notf
Other than visually, can you determine if your pipeline is leaking?
Yes No $
Do you have written contingency plans for handling leaks from your outsideblock-limits pipelines?
Yes [] No [] N/A
If more than one owner is involved, do they concur with your emergency contingency plans?
Yes[f No [] In a pipeline emergency, will you, as
the owner, normally respond?
Yes [] No [] N/A
If others are expected to respond, have they been included in training/planning necessary to handle a pipeline leak with your materials?
Yes 0^ NoQ Is there a list of owner contacts
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available to those responding to the emergency?
B 20.
Yes 0^ No []
Is the list of contacts dated and periodically updated?
B 21.
Is Distribution E/R included on the "pipeline emergency" call list?
B 22.
N/A[]
If you handle flammable or combustible materials, are there provisions for grounding containers at the take-off point stations?
B 23.
What deficiencies presently exist on vour niDeline systems?
^r
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