Process safety programs require that all equipment be designed, operated and maintained to the highest standards. In practical terms this requirement means that if the equipment and piping always retains its integrity, i.e., if it does not leak, then then highly hazardous materials will not be released. (The term used by OSHA — Mechanical Integrity — is too limiting; integrity programs should incorporate instrumentation and other non-mechanical items. The phrase ‘Asset Integrity’ is a better choice.)
Piping and valves have their own topic page.
The following is a list of the typical equipment covered by a process safety asset integrity program.
There are many regulations, codes and standards to do with the mechanical integrity element of process safety management programs. Some of the key standards-setting bodies are:
In the United States important process safety management regulations are published by:
Articles, safety moments and other publications are listed below.
You are welcome to use this Safety Moment in your workplace. But there are restrictions — please read Use of Safety Moments.
Copyright © Ian Sutton. 2018. All Rights Reserved.
September 2022
OSHA has opened the Process Safety standard for comment and revision. One of the items on their list is to do with storage tanks. Item II.1 reads,
Clarifying the exemption for atmospheric storage tanks
After a piece of equipment or piping that operates under pressure has been opened and then reassembled (buttoned up) it must be pressure tested before being put back into service.
Process lines, piping and valves frequently become plugged. If line pluggage is a recurring problem it is best to try and identify ways in which the problem can be prevented from occurring. If that solution is not possible then valves, drains, tees and connections should be designed so that it is possible to remove the pluggage safely and with minimum time and expense.
The words ‘siting’ and ‘layout’ are often used interchangeably, but, strictly speaking, they have different meanings. Siting is concerned with the location of a facility.
An updated version of this page is available here.
Copyright © Ian Sutton. 2024. All Rights Reserved.
Personal Protective Equipment (PPE) is the last line of defense for keeping a person safe. Every effort should be made to protect the wearer ahead of time. The Irish Health & Safety Authority provides the following precautionary statements with regard to PPE.
Safety Moment #57: Equipment Spacing (Pumps/Fireproofed Pipe Racks) described the layout of pumps in a process or energy facility. Continuing the discussion, this Safety Moment describes some of the issues to be considered with regard to the layout of storage tanks, sometimes referred to as “API Tanks”.
Pump seals are a source of leaks in process and energy facilities. Moreover, the discharged liquid will normally be at high pressure, so it can travel a long distance and/or form a spray. Therefore, when laying out a facility it is important to make sure that pumps are located at a safe distance from other equipment and piping. (If the facility is already constructed and in operation it is still useful to consider spacing and layout guidelines.
The Primer Distillation is priced at $25 (U.S.) It can be purchased here.
