precision refrigeration ammonia training€¦ · pressure vessels and storage tanks. ... a more...

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Prepared By: Steve JonesMay 9, 2018

Precision Refrigeration Ammonia TrainingMECHANICAL INTEGRITY

Mechanical Integrity

Scope of Training Regulatory Agencies Frequency of Inspections Record Keeping What to Look For

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Mechanical Integrity andThe Alphabet Agencies

Why Have A Mechanical Integrity Program? It’s The Law

OSHA- Occupational Safety and Health Administration 29 CFR 1910.119

CALARP- California Accidental Release Prevention Program Title 19 Division 2 Chapter 4.5

EPA- Environmental Protection Agency Risk Management Program 40 CFR Part 68

Mechanical Integrity and The Alphabet Agencies

According to OSHA, the necessary elements of a good mechanical integrity (MI) program are:

Establish and implement written procedures to maintain the integrity of process equipment.

Train employees and contractors involved in maintaining the integrity of equipment. Perform periodic inspection and testing, following “recognized and generally

accepted good engineering practices,” and document that inspections have been done.

Correct equipment deficiencies before further use or in a safe and timely manner. Develop a quality assurance program to ensure that: Equipment for new plants is suitable for use in the process, and is properly installed All maintenance materials, spare parts and equipment are suitable for intended use.

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OSHA Process Safety Management 29 CFR 1910.119. Threshold Quantity of 10000 pounds of Anhydrous Ammonia.

29 CFR 1910.119(j) Requires the Establishment of a Written Mechanical Integrity Program.

PSM Mechanical Integrity Requirements Apply to the Following Equipment:

Pressure Vessels and Storage Tanks. Piping Systems and Associated Valves. Safety Relief Systems. Emergency Shutdown Systems Controls Pumps


CALARP CCR Title 19 Division 2 Chapter 4.5. Threshold Quantity of 500 pounds of Anhydrous Ammonia.

CALARP has Three Program Levels A Written Maintenance Program is Required for Program Level 2 A Written Mechanical Integrity Program is Required for Program Level 3 For Purposes of Expediency Our Focus Will be on Program Level 3 CALARP CCR 19 Division 2 Chapter 4.5 Section 2760.5 Apply to the Following Equipment: Pressure Vessels Including Storage Tanks Piping Systems Including Piping Components Relief and Vent Systems and Devices Emergency Shut Down Systems Controls Pumps

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OSHA PSM, EPA RMP Level 3, and CALARP Program Level 3 have the Same Requirement for Inspection and Testing:

Inspection and testing must be performed on process equipment, using procedures that follow recognized and generally accepted good engineering practices. The frequency of inspections and tests of process equipment must conform with manufacturers' recommendations and good engineering practices, or more frequently if determined to be necessary by prior operating experience. Each inspection and test on process equipment must be documented, identifying the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test.

Equipment deficiencies outside the acceptable limits defined by the process safety information must be corrected before further use. In some cases, it may not be necessary that deficiencies be corrected before further use, as long as deficiencies are corrected in a safe and timely manner, when other necessary steps are taken to ensure safe operation.


Frequency of Inspections Inspections Can be Conducted: Daily Weekly Bi-Weekly Monthly Quarterly Semi- Annually Annually And Every 5 Years

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Mechanical IntegrityFrequency of Inspections

The Following are Resources for Determining the Type and Frequency of Inspections:

The Equipment Manufactures Maintenance Manuals IIAR International Institute of Ammonia Refrigeration Bulletin 110 Start

Up, Inspection and Maintenance of Ammonia Mechanical Refrigeration Systems (www.iiar.org)

IIAR Bulletin 109 Minimum Safety Criteria for a Safe Ammonia Refrigeration System

The Industrial Refrigeration Consortium Mechanical Integrity Guide Book (www.irc.wisc.edu)


The Following Charts are Examples Only of Mechanical Integrity Inspection and Frequency.

Mechanical Integrity Programs Should Not be Generic A Written Mechanical Integrity Program Should be Tailored to the

Process Equipment at Your Facility. The Written Mechanical Integrity Program Should Refer to the

Manufactures Recommended Maintenance for the Equipment Involved in the Process.

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Mechanical IntegrityFrequency of Inspections• Guideline From IIAR Bulletin 110 Compressors


Guidelines From IIAR Bulletin110 Vessel and Heat Exchangers

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Guidelines From IIAR Bulletin 110 Ammonia Pumps

Mechanical IntegrityFrequency of Inspections Guideline From IIAR Bulletin 110 Valves and Sensing Devices

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Guideline From IIAR Bulletin 110 Piping


Guideline From IIAR Bulletin 110 Pressure Relief Devices

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Guideline From IIAR Bulletin 110 Ammonia Charge


Guideline From IIAR Bulletin 110 Oil

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Mechanical Integrity Frequency of Inspections

Recommended Maintenance Schedule for a Frick Compressor The Manufactures Maintenance Schedule Should Always be Followed


IIAR Bulletin 109 Minimum Safety Criteria for a Safe Ammonia Refrigeration System.

Should be Performed at Least Annually. Comprehensive Evaluations of all Ammonia Refrigeration Process

Equipment Comprehensive Evaluation of Process Safety Information. Requires

Documentation for Vessels and Process Equipment be Verified. Ensures All System Safeties are Tested and Evaluated. Gives an OSHA or CALARP Inspector Clear Documentation of

Annual Safety Inspections and Tests.

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Five Year Mechanical Integrity Inspection In regards to good engineering practice for ammonia refrigeration systems, the two primary

documents that are considered RAGAGEP (recognized and generally accepted good engineering practice) are:

IIAR Bulletin No. 109 Guidelines for: IIAR Minimum Safety Criteria for a Safe Ammonia Refrigeration System

IIAR Bulletin No. 110 Guidelines for: Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems

Here is what each of those documents has to say about a 5-year mechanical integrity inspection: IIAR Bulletin No. 110 §6.4.4.1

At least every five years, the annual inspection of the vessels and heat exchangers shall be carried out by a competent person independent of immediate commercial and production pressures for that installation, who shall carry out whatever examinations and tests he may consider necessary in order to determine that the equipment is safe for further use or in order to specify such repairs that may be necessary.

IIAR Bulletin No. 109 §5.3A more thorough inspection of an ammonia refrigeration system should be conducted by a competent ammonia refrigeration engineer and/or fire safety official and/or other authority every five years.

Mechanical IntegrityRecord Keeping

Record Keeping The owner or operator shall document each inspection and test

that has been performed on process equipment. The documentation shall identify the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test.

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Example of a Daily Log Sheet From IIAR Bulletin 110


Example of a Weekly Inspection Sheet

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Example of a Monthly Inspection Sheet

Mechanical IntegrityRecord KeepingMechanical Integrity Maintenance and

Inspection Records Should be Kept for Five Years.

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Mechanical IntegrityWhy Have a Mechanical Integrity Program?Chemicals From a Leaking Evaporative Condenser Have Corroded the Discharge Line.The Relief Header is Corroded and Changing Size

Mechanical IntegrityInsulation Vapor Barrier BreachesHigh Level Float DisconnectedInsulation Removed

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Mechanical IntegrityEvaporator Plugged with Dirt and Debris

Mechanical IntegrityAngle Valve Missing a Plug

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Mechanical IntegrityHigh Level Float Switch Missing


What To Look For. Mechanical Integrity is About Safety If Your Mechanical Integrity Program is Using “Breakdown

Maintenance” You Need to Review and Fix Your Program. Breakdown Maintenance can Result in An Ammonia Release. The Philosophy of “Waiting Till it Breaks” Can Cost Your Company More

Money in Down Time and Repair Costs. According to some corporate managers, there can be positive benefits

from Process Safety Management: “Process safety management is intended to help you recognize,

understand and control all your process hazards. If you do that, you’re going to understand and control your business; it runs better. . . it’s more efficient and your quality’s higher.”

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For Questions or Comments Contact:Dana ChiaravallottiEmail [email protected] Refrigeration9726 Klingerman StSouth El Monte Ca 91733626-443-8882

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