Mechanical Integrity

1. Mechanical Integrity Equipment Deficiencies

2. Lesson Objectives • Describe Actions When Equipment Deficiencies Found in Operating Equipment • Describe Written Procedures and Documented Rationale Required to Safely Operate Equipment Until Deficiencies can be Corrected

3. Discussion • Unsafe Deficiencies Must Be Corrected ASAP or Provisions Made to Assure Safe Operation Until Correction • Examples of Deficiencies • Equipment Outside Acceptable Safety Limits • Failure • Material or System Outside Acceptable Limits • Cannot Perform Intended Function • Examples of Deficiencies • Loss of Vessel Strength Due to Corrosion • Leaks of HHCs • Blind Left Under Relief Valve by Mistake • Critical Switch is Off Calibration • Revised Temporary Operating Procedures May be Required to Continue Operations

4. Some Tips to Determine Action Plan • Confirm Outside Accepted Limits • Determine if Shutdown is Required to Restore MI • Determine Safety Consequences of Shutting Down Now Vs. Later • Determine What Steps Can be Taken to Accept Consequences of Failure • Bypass Equipment and Adjust Operations • Temporary Repairs to Stop Leaks • Temporary Hookup of Substitute Equipment • Reduction of Operations to Within Acceptable Limits

5. Justification for Continued Operation In Deficient Condition • Why the Decision was Made to Continue • What Was Done To The Equipment Or Process To Assure Process Safety • Analysis • Monitoring • Reduced Capacity • Other