mechanical integrity
“OSHA believes it is important to maintain the mechanical
integrity of critical process equipment to ensure it is designed and installed
correctly and operates properly. …. The employer must establish and implement
written procedures to maintain the ongoing integrity of process equipment.
Employees involved in maintaining the ongoing integrity of process equipment
must be trained in an overview of that process and its hazards and trained in
the procedures applicable to the employees’ job tasks. Inspection and testing
must be performed on process equipment, using procedures that follow recognized
and generally accepted good engineering practices.” OSHA Publication 3132
Mechanical Integrity incorporates many aspects of the operation of the ammonia refrigeration system. These include: The Operation and maintenance manuals, Vessel data reports, the system rounds log, annual ammonia inspections, and mechanical Integrity inspections.
Each shift should begin with a system log or daily rounds inspection of the refrigeration system. The System Log provides a checklist to be used by the operators daily to check the operation of the ammonia refrigeration system. Closely tied to the System Log is the Master Maintenance Log, an ongoing diary of Ammonia refrigeration system activities. By structuring these components properly the operator can be more productive and multiple levels of safeguards can be established.
8a. Develop the Mechanical Integrity Policy
Wagner-Meinert, LLC will develop a Mechanical Integrity Policy. The policy will then be reviewed with facility personnel and finalized before being turned over to facility employees for implementation.
8b. Compile Operation and Maintenance Manuals
Wagner-Meinert, LLC would assemble an Operation and Maintenance Library covering the equipment in the Ammonia Refrigeration System. The manuals would be organized in the same order as the Equipment Information. Typical information includes:
1. Manufacturer’s Operation and Maintenance Information
2. Manufacturer’s spare parts lists
3. Cut sheets on hand and control valves
4. General Safety guideline from manufacturers (vessel safety, etc.)
8c. Acquire manufacturer’s data reports and Certified Drawings for vessels
Wagner-Meinert, LLC would attempt to acquire manufacturer’s Data Reports and Certified Drawings. In some instances this information is no longer available. If information is not available, this will be noted.
8d. Develop a System Rounds Log
Wagner-Meinert, LLC will construct the System Rounds Log with ease of use in mind. The operator’s time is very valuable. We would propose a sheet containing vital system readings, compressor operating conditions, vessel levels, weather conditions, and a general walk through.
During the review of the Standard Operating Procedures additional items may be discovered which need to be added to the Daily Rounds Log. Additional items may be discovered during the Hazard Review or Process Hazard Analysis.
8e. Conduct a Mechanical Integrity Inspection
The Mechanical Integrity inspection will be conducted in accordance with IIAR Bulletin 109 less the source codes referenced in Section 6 of IIAR Bulletin 109 with additional criteria added (see additional inspections below).
Compressor Inspection criteria:
The nameplate information shall be verified as per IIAR’s checklist.
Limitations established by the manufacturer shall be verified as per IIAR’s checklist.
The motor shall be inspected visually to confirm that it appears to be in good working condition.
The compressor installation shall be inspected to confirm that suction and discharge stop valves are installed as well as a suction and discharge check valve.
The compressor shall be visually inspected for signs of alteration.
The following items shall be checked to confirm that they are operable: Low pressure cutout switch, High pressure cutout switch, and Low oil pressure cutout switch (if the compressor uses forced feed lubrication). These shall be checked in the quickest fashion possible. Please note malfunction of the compressor due to failure of the control as well as any negative repercussions and functionality of the test remain the responsibility of the facility.
The installation of indicating devices shall be verified. These include: compressor suction pressure, discharge pressure, oil pressure (if the compressor used forced lubrication), and discharge temperature.
The compressor shall be visually inspected to determine if there are any excessive vibrations. Please note this is a visual test only and does not include any vibration analysis.
The compressor anchor bolts shall be visually inspected to determine if they are loose.
The general cleanliness of the compressor shall be evaluated visually.
Evaporative Condenser Inspection Criteria:
Visual inspections shall be performed to determine if there are any obvious issues related to support and anchorage.
An assessment shall be made as to the feasibility of safe access for employees during normal service.
The condenser fan(s) and drive(s) shall be observed (visually) to determine if they are free of excessive vibrations.
The condenser shall be visually inspected for corrosion.
The coil of the condenser shall be inspected visually from the exterior of the condenser to determine if there is any scale or dirt build-up.
The mist eliminators shall be inspected visually from the exterior of the condenser to determine if there is any scale or dirt build-up.
The water sump shall be inspected visually from the exterior of the condenser to determine if there is any scale or dirt build-up.
The efficiency (visual determination of water flow) shall be checked from the exterior of the unit.
Shell and Tube Heat Exchanger Inspection criteria:
The nameplate information shall be verified as per IIAR’s checklist.
The operating pressure (based on the assumption that accurate pressure gauges are installed) shall be reviewed to determine that it is operating within the pressure and temperature limits established by the manufacturer as listed on the nameplate.
A determination shall be made visually, as to the need for additional inspections by a professional engineer or ASME inspector.
The Shell and Tube Heat Exchanger shall be visually inspected for signs of alteration.
A visual determination shall be made as to the adequacy of the component marker (unique identification, operating temperature, and pressure).
The installation of a visual level indicating device shall be verified.
Where applicable, a determination shall be made through observation, that the visual indicating device is protected from traffic hazards.
Vessel Inspection criteria:
The nameplate information shall be verified as per IIAR’s checklist.
The operating pressure (based on the assumption that accurate pressure gauges are installed) shall be reviewed to determine that it is operating within the pressure and temperature limits established by the manufacturer as listed on the nameplate.
A determination shall be made visually, as to the need for additional inspections by a professional engineer or ASME inspector.
The vessel shall be visually inspected for signs of alteration.
A visual determination shall be made as to the adequacy of the component marker (unique identification, operating temperature, and pressure).
The installation of a visual level indicating device shall be verified.
Where applicable a determination shall be made through observation, that the visual level indicating device is protected from traffic hazards.
Forced Air Evaporator Inspection criteria:
A visual determination shall be made as to the adequacy of anchors and supports associated with the forced air evaporators.
A determination shall be made through observation, that the forced air evaporator is protected from traffic hazards.
A visual determination shall be made as to whether the forced air evaporator or the associated piping is free of excessive ice build-up.
The forced air evaporator shall be inspected visually from the exterior of the evaporator to determine if there is any significant corrosion.
Determine the cleanliness of the coil.
Determine the cleanliness of the drain pan.
Refrigerant Pump Inspection criteria:
A visual determination shall be made as to the installation of isolation valves (please note this does not assure the operation of the isolation valves).
A determination based on manufacturer’s information as to the suitability of service of the refrigerant pump.
A determination as to the installation of a hydrostatic or pressure differential relief device for pressure protection of the refrigerant.
Piping System Inspection criteria:
An inspection of the maintenance or repair log shall be made to determine if mechanical fasteners are periodically checked for tightness or that mechanical fasteners are repaired.
A determination shall be made through observation, that the piping system is protected from traffic hazards.
A determination shall be made through observation, that the un-insulated piping is not corroded.
A determination shall be made through observation, as to the condition of vapor barriers on insulated piping.
A visual determination shall be made as to the adequacy of the pipe markers (use and direction of flow).
A visual determination shall be made as to the adequacy of structural support.
Ammonia Machine Room Ventilation Inspection criteria:
A verification shall be made that a ventilation calculation is on file.
A verification of the installation and function of the sail switch.
A verification of the alarm activation when the continuous ventilation system is de-activated by utilizing the disconnect.
A verification of the functionality upon activation (not calibration) of the engine room ammonia detector.
Pressure Relief Device Inspection criteria:
A determination shall be made through observation, as to the installation of relief devices where needed.
A determination shall be made through observation, as to the installation of stop valves between the pressure relief device and the component to be protected.
A visual determination shall be made as to determine that pressure relief devices are installed in such fashion that they are readily accessible for inspection and replacement.
A determination shall be made through observation, as to the set pressure of the pressure relief device being equal to or less than the design pressure of the component to be protected.
A visual determination shall be made as to determine that pressure relief devices are sealed at their set pressure by the manufacturer. (This is to be done through observation and as such is subject to the inspectors opinion as to whether a seal is factory installed or field installed. Since this determination is very difficult to ascertain. This inspection is limited to answering the question “Is a seal installed?”).
A verification shall be made to determine if a relief calculation is on file and if the calculation has determined that relief valves and relief piping are adequate.
A determination shall be made as to whether the facility has replaced or inspected cleaned and tested pressure relief devices after five years of service.
General Ammonia Refrigeration System Inspection criteria:
A determination shall be made through observation that instruments are in working order. (This is limited to observations that can be made through the course of the inspectors time at the facility).
The high level shutdowns associated with the accumulators or intercoolers shall be tested utilizing a magnet to determine if they are wired to shutdown the associated compressors. Note this does not verify the mechanical functionality of the float mechanism.
A verification shall be made to determine if main shut-off valves are readily accessible and identified with a prominent sign.
A determination shall be made to verify that a prominent sign is installed outlining: Name and address of the installer, refrigerant type and amount, oil type and amount, and field test pressures.
A determination shall be made to verify that a prominent sign is installed outlining: emergency operating instructions, and phone numbers of safety and operating personnel.
A determination shall be made to verify that a prominent sign is installed outlining: Emergency evacuation routes and responsible persons.
A determination shall be made to verify that the system is free of readily detected ammonia leaks.
A determination shall be made to verify that the system is free of abnormal sounds or vibrations.
A determination shall be made to verify that an eyewash and shower are installed just outside of the ammonia engine room. (This determination shall be to verify the installation and not the operation of the eyewash and shower).
A determination shall be made to verify that an eyewash and shower are installed just inside of the ammonia engine room. (This determination shall be to verify the installation and not the operation of the eyewash and shower).
A determination shall be made to verify that a self-contained breathing apparatus is located outside of, but near the exit door of the engine room. (This determination shall be to verify the installation, and not the operation of or the fitness of duty of the self-contained breathing apparatus).
A determination shall be made to verify that an additional self-contained breathing apparatus is available. (This determination shall be to verify the installation, and not the operation of or the fitness of duty of the self-contained breathing apparatus).
A determination shall be made as to whether there are any piping obstructions in the exit of the engine room.
A determination shall be made to verify that a log is being maintained to record maintenance activities associated with the ammonia refrigeration system.
A determination shall be made to verify that a log is being maintained to record oil charging and draining activities associated with the ammonia refrigeration system.
Non-Destructive Testing (NDT):
We have not included non-destructive testing in our proposal. We can provide non-destructive testing if required for an additional fee.
Additional Inspections:
Field tests would be conducted on equipment and equipment safeties per our prepared checklist. Wagner-Meinert, LLC uses a checklist designed to incorporate the questions provided by IIAR and supplemented by Wagner-Meinert in those areas that were in our opinion deficient.
This inspection includes the information outlined in the Mechanical Integrity inspection above, as well additional safeties, and more importantly, more through methods. These include items such as: physically filling the level columns as opposed to tripping the switch with a magnet.
Tests will include: Visual inspections of all system components. Testing high level alarms and shutdowns on the vessels used for compressor safeties. Testing the alarms and shutdowns on all compressors. Visual inspection of the insulation vapor barrier. Inspection of the ventilation system components. Piping, inspections of the relief system, and general system inspections.
We have anticipated using the ladders and on site lifts to access equipment.
During the course of the inspection, items requiring repair may be discovered. Items which can be easily adjusted, repaired, or replaced such as compressor safeties, float switches, contacts, etc. will be repaired during the inspection on a time and material basis (not included in the costs listed below). Larger repair items will be noted in the inspection for future consideration.
We utilize digital photography to document some of the deficiencies. Printed copies of all referenced photos will be provided as part of the report.
While testing the equipment, sections of the system will be required to be shutdown. This may require the entire system to be shut down for periods of about 30 minutes at a time. This should not affect product storage. However, it may interfere with production.
At the conclusion of the study, a written report will be issued outlining the findings of the study. Included in the report is a summary listing the items requiring attention. Also, included are recommended actions. An electronic copy of the report for archive purposes (in .PDF format) will be included with the report. A listing of the follow-up items will be made available for you to utilize in recording follow-up actions.
Mechanical Integrity incorporates many aspects of the operation of the ammonia refrigeration system. These include: The Operation and maintenance manuals, Vessel data reports, the system rounds log, annual ammonia inspections, and mechanical Integrity inspections.
Each shift should begin with a system log or daily rounds inspection of the refrigeration system. The System Log provides a checklist to be used by the operators daily to check the operation of the ammonia refrigeration system. Closely tied to the System Log is the Master Maintenance Log, an ongoing diary of Ammonia refrigeration system activities. By structuring these components properly the operator can be more productive and multiple levels of safeguards can be established.
8a. Develop the Mechanical Integrity Policy
Wagner-Meinert, LLC will develop a Mechanical Integrity Policy. The policy will then be reviewed with facility personnel and finalized before being turned over to facility employees for implementation.
8b. Compile Operation and Maintenance Manuals
Wagner-Meinert, LLC would assemble an Operation and Maintenance Library covering the equipment in the Ammonia Refrigeration System. The manuals would be organized in the same order as the Equipment Information. Typical information includes:
1. Manufacturer’s Operation and Maintenance Information
2. Manufacturer’s spare parts lists
3. Cut sheets on hand and control valves
4. General Safety guideline from manufacturers (vessel safety, etc.)
8c. Acquire manufacturer’s data reports and Certified Drawings for vessels
Wagner-Meinert, LLC would attempt to acquire manufacturer’s Data Reports and Certified Drawings. In some instances this information is no longer available. If information is not available, this will be noted.
8d. Develop a System Rounds Log
Wagner-Meinert, LLC will construct the System Rounds Log with ease of use in mind. The operator’s time is very valuable. We would propose a sheet containing vital system readings, compressor operating conditions, vessel levels, weather conditions, and a general walk through.
During the review of the Standard Operating Procedures additional items may be discovered which need to be added to the Daily Rounds Log. Additional items may be discovered during the Hazard Review or Process Hazard Analysis.
8e. Conduct a Mechanical Integrity Inspection
The Mechanical Integrity inspection will be conducted in accordance with IIAR Bulletin 109 less the source codes referenced in Section 6 of IIAR Bulletin 109 with additional criteria added (see additional inspections below).
Compressor Inspection criteria:
The nameplate information shall be verified as per IIAR’s checklist.
Limitations established by the manufacturer shall be verified as per IIAR’s checklist.
The motor shall be inspected visually to confirm that it appears to be in good working condition.
The compressor installation shall be inspected to confirm that suction and discharge stop valves are installed as well as a suction and discharge check valve.
The compressor shall be visually inspected for signs of alteration.
The following items shall be checked to confirm that they are operable: Low pressure cutout switch, High pressure cutout switch, and Low oil pressure cutout switch (if the compressor uses forced feed lubrication). These shall be checked in the quickest fashion possible. Please note malfunction of the compressor due to failure of the control as well as any negative repercussions and functionality of the test remain the responsibility of the facility.
The installation of indicating devices shall be verified. These include: compressor suction pressure, discharge pressure, oil pressure (if the compressor used forced lubrication), and discharge temperature.
The compressor shall be visually inspected to determine if there are any excessive vibrations. Please note this is a visual test only and does not include any vibration analysis.
The compressor anchor bolts shall be visually inspected to determine if they are loose.
The general cleanliness of the compressor shall be evaluated visually.
Evaporative Condenser Inspection Criteria:
Visual inspections shall be performed to determine if there are any obvious issues related to support and anchorage.
An assessment shall be made as to the feasibility of safe access for employees during normal service.
The condenser fan(s) and drive(s) shall be observed (visually) to determine if they are free of excessive vibrations.
The condenser shall be visually inspected for corrosion.
The coil of the condenser shall be inspected visually from the exterior of the condenser to determine if there is any scale or dirt build-up.
The mist eliminators shall be inspected visually from the exterior of the condenser to determine if there is any scale or dirt build-up.
The water sump shall be inspected visually from the exterior of the condenser to determine if there is any scale or dirt build-up.
The efficiency (visual determination of water flow) shall be checked from the exterior of the unit.
Shell and Tube Heat Exchanger Inspection criteria:
The nameplate information shall be verified as per IIAR’s checklist.
The operating pressure (based on the assumption that accurate pressure gauges are installed) shall be reviewed to determine that it is operating within the pressure and temperature limits established by the manufacturer as listed on the nameplate.
A determination shall be made visually, as to the need for additional inspections by a professional engineer or ASME inspector.
The Shell and Tube Heat Exchanger shall be visually inspected for signs of alteration.
A visual determination shall be made as to the adequacy of the component marker (unique identification, operating temperature, and pressure).
The installation of a visual level indicating device shall be verified.
Where applicable, a determination shall be made through observation, that the visual indicating device is protected from traffic hazards.
Vessel Inspection criteria:
The nameplate information shall be verified as per IIAR’s checklist.
The operating pressure (based on the assumption that accurate pressure gauges are installed) shall be reviewed to determine that it is operating within the pressure and temperature limits established by the manufacturer as listed on the nameplate.
A determination shall be made visually, as to the need for additional inspections by a professional engineer or ASME inspector.
The vessel shall be visually inspected for signs of alteration.
A visual determination shall be made as to the adequacy of the component marker (unique identification, operating temperature, and pressure).
The installation of a visual level indicating device shall be verified.
Where applicable a determination shall be made through observation, that the visual level indicating device is protected from traffic hazards.
Forced Air Evaporator Inspection criteria:
A visual determination shall be made as to the adequacy of anchors and supports associated with the forced air evaporators.
A determination shall be made through observation, that the forced air evaporator is protected from traffic hazards.
A visual determination shall be made as to whether the forced air evaporator or the associated piping is free of excessive ice build-up.
The forced air evaporator shall be inspected visually from the exterior of the evaporator to determine if there is any significant corrosion.
Determine the cleanliness of the coil.
Determine the cleanliness of the drain pan.
Refrigerant Pump Inspection criteria:
A visual determination shall be made as to the installation of isolation valves (please note this does not assure the operation of the isolation valves).
A determination based on manufacturer’s information as to the suitability of service of the refrigerant pump.
A determination as to the installation of a hydrostatic or pressure differential relief device for pressure protection of the refrigerant.
Piping System Inspection criteria:
An inspection of the maintenance or repair log shall be made to determine if mechanical fasteners are periodically checked for tightness or that mechanical fasteners are repaired.
A determination shall be made through observation, that the piping system is protected from traffic hazards.
A determination shall be made through observation, that the un-insulated piping is not corroded.
A determination shall be made through observation, as to the condition of vapor barriers on insulated piping.
A visual determination shall be made as to the adequacy of the pipe markers (use and direction of flow).
A visual determination shall be made as to the adequacy of structural support.
Ammonia Machine Room Ventilation Inspection criteria:
A verification shall be made that a ventilation calculation is on file.
A verification of the installation and function of the sail switch.
A verification of the alarm activation when the continuous ventilation system is de-activated by utilizing the disconnect.
A verification of the functionality upon activation (not calibration) of the engine room ammonia detector.
Pressure Relief Device Inspection criteria:
A determination shall be made through observation, as to the installation of relief devices where needed.
A determination shall be made through observation, as to the installation of stop valves between the pressure relief device and the component to be protected.
A visual determination shall be made as to determine that pressure relief devices are installed in such fashion that they are readily accessible for inspection and replacement.
A determination shall be made through observation, as to the set pressure of the pressure relief device being equal to or less than the design pressure of the component to be protected.
A visual determination shall be made as to determine that pressure relief devices are sealed at their set pressure by the manufacturer. (This is to be done through observation and as such is subject to the inspectors opinion as to whether a seal is factory installed or field installed. Since this determination is very difficult to ascertain. This inspection is limited to answering the question “Is a seal installed?”).
A verification shall be made to determine if a relief calculation is on file and if the calculation has determined that relief valves and relief piping are adequate.
A determination shall be made as to whether the facility has replaced or inspected cleaned and tested pressure relief devices after five years of service.
General Ammonia Refrigeration System Inspection criteria:
A determination shall be made through observation that instruments are in working order. (This is limited to observations that can be made through the course of the inspectors time at the facility).
The high level shutdowns associated with the accumulators or intercoolers shall be tested utilizing a magnet to determine if they are wired to shutdown the associated compressors. Note this does not verify the mechanical functionality of the float mechanism.
A verification shall be made to determine if main shut-off valves are readily accessible and identified with a prominent sign.
A determination shall be made to verify that a prominent sign is installed outlining: Name and address of the installer, refrigerant type and amount, oil type and amount, and field test pressures.
A determination shall be made to verify that a prominent sign is installed outlining: emergency operating instructions, and phone numbers of safety and operating personnel.
A determination shall be made to verify that a prominent sign is installed outlining: Emergency evacuation routes and responsible persons.
A determination shall be made to verify that the system is free of readily detected ammonia leaks.
A determination shall be made to verify that the system is free of abnormal sounds or vibrations.
A determination shall be made to verify that an eyewash and shower are installed just outside of the ammonia engine room. (This determination shall be to verify the installation and not the operation of the eyewash and shower).
A determination shall be made to verify that an eyewash and shower are installed just inside of the ammonia engine room. (This determination shall be to verify the installation and not the operation of the eyewash and shower).
A determination shall be made to verify that a self-contained breathing apparatus is located outside of, but near the exit door of the engine room. (This determination shall be to verify the installation, and not the operation of or the fitness of duty of the self-contained breathing apparatus).
A determination shall be made to verify that an additional self-contained breathing apparatus is available. (This determination shall be to verify the installation, and not the operation of or the fitness of duty of the self-contained breathing apparatus).
A determination shall be made as to whether there are any piping obstructions in the exit of the engine room.
A determination shall be made to verify that a log is being maintained to record maintenance activities associated with the ammonia refrigeration system.
A determination shall be made to verify that a log is being maintained to record oil charging and draining activities associated with the ammonia refrigeration system.
Non-Destructive Testing (NDT):
We have not included non-destructive testing in our proposal. We can provide non-destructive testing if required for an additional fee.
Additional Inspections:
Field tests would be conducted on equipment and equipment safeties per our prepared checklist. Wagner-Meinert, LLC uses a checklist designed to incorporate the questions provided by IIAR and supplemented by Wagner-Meinert in those areas that were in our opinion deficient.
This inspection includes the information outlined in the Mechanical Integrity inspection above, as well additional safeties, and more importantly, more through methods. These include items such as: physically filling the level columns as opposed to tripping the switch with a magnet.
Tests will include: Visual inspections of all system components. Testing high level alarms and shutdowns on the vessels used for compressor safeties. Testing the alarms and shutdowns on all compressors. Visual inspection of the insulation vapor barrier. Inspection of the ventilation system components. Piping, inspections of the relief system, and general system inspections.
We have anticipated using the ladders and on site lifts to access equipment.
During the course of the inspection, items requiring repair may be discovered. Items which can be easily adjusted, repaired, or replaced such as compressor safeties, float switches, contacts, etc. will be repaired during the inspection on a time and material basis (not included in the costs listed below). Larger repair items will be noted in the inspection for future consideration.
We utilize digital photography to document some of the deficiencies. Printed copies of all referenced photos will be provided as part of the report.
While testing the equipment, sections of the system will be required to be shutdown. This may require the entire system to be shut down for periods of about 30 minutes at a time. This should not affect product storage. However, it may interfere with production.
At the conclusion of the study, a written report will be issued outlining the findings of the study. Included in the report is a summary listing the items requiring attention. Also, included are recommended actions. An electronic copy of the report for archive purposes (in .PDF format) will be included with the report. A listing of the follow-up items will be made available for you to utilize in recording follow-up actions.
