)‫ك‬.‫م‬.

‫شركة صناعة الكيماويات البترولية (ش‬

Petrochemical Industries Co. (K.S.C.)
Process Safety Management System

Fertilizer Manufacturing

Mechanical Integrity “MI”

Procedure

ISSUE 1
September 2005

Controlled / Uncontrolled Copy

Issued by: Mechanical Integrity Team Title: PIC Engineer

Reviewed by: Majed AL-Shammary Title: Sr. Inspection &Corrosion
Approved by: Abdallah Al-Swailem Title: PSM Chairperson

 Confidentiality *

This information is and shall remain confidential to The PIC Fertilizer Manufacturing and selected
external organizations. Accordingly, PIC Fertilizer Manufacturing retains all copyrights and no
copying in any format of this document is permitted without written authorization from PSM
Chairperson.

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Petrochemical Industries Co. (K.S.C.)
Process Safety Management System

2 Distribution List

PSM Coordinator – Master Copy

Chairman & Managing Director
PSM Committee Chairperson

3 Revision Issue

Issue and revision history as per Achiever Plus document

history

4 Table of Contents

S/No. Description
1 Authorization 1
2 Distribution List 2
3 Revision Issue 2
4 Table of Contents 2
5 Introduction 3
6 Purpose 3
7 Scope 3
8 Responsibility 3
9 References 4
10 Abbreviations 4
11 Action 5

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 )‫ك‬.‫م‬.‫شركة صناعة الكيماويات البترولية (ش‬
Petrochemical Industries Co. (K.S.C.)
Process Safety Management System

5 INTRODUCTION

It is the policy of Petrochemical Industries Company (PIC) to establish a process

safety management (PSM) system, in order to provide a safety culture,
management leadership, and achieve operating excellence. Mechanical Integrity
(MI) is one of the main elements in the PSM system. Mechanical integrity covers
the facility (equipment, piping, instrumentation, electrical system, and other
physical items) to ensure they are maintained to the appropriate standards, and
chance of failure of these systems is minimized through the selection of
inspection methods that are appropriate with regard to both technique and
frequency for the systems being checked.

6 PURPOSE

The purpose of this document is to outline a plan for development and

implementation of mechanical integrity while facilities are in operation.

7 SCOPE

Mechanical integrity procedure shall cover all equipment in plants within PIC Fertilizer
Plants battery limits from initial installation throughout lifetime of the facility and up
to dismantlement.

8 RESPONSIBILITY

 PSM chairperson is responsible for maintaining, updating, modifying and ensuring

the effective implementation of this procedure.
 Technical Services Manager is responsible for executing and maintaining the
program.

9 REFERENCES

 PIC PSM MANUAL

 DuPont Process Safety & Risk Management Work Book

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 )‫ك‬.‫م‬.‫شركة صناعة الكيماويات البترولية (ش‬
Petrochemical Industries Co. (K.S.C.)
Process Safety Management System

10 ABBREVIATIONS

 PIC – Petrochemical Industries Company

 PSM – Process Safety Management
 MI – Mechanical Integrity
 SHE- Safety, Health and Environmental

11 ACTION

The MI process during equipment operational phase is depicted in Figure 1.

11.1 Equipment Survey

The MI program starts by conducting a complete survey of equipment items at a

plant. Developing a plant equipment hierarchy will facilitate this task. The
equipment hierarchy helps the surveyor understand the parent/child relationships
between systems, subsystems and equipment items.

Information related to equipment hierarchy elements (equipment/functional

location) are collected and stored with the element. The information includes
upper and lower design and operating limits, applicable design codes, and
references to drawing and other technical documentation. Equipment
datasheets, when available, are the best source for information regarding
equipment and their operating context.

11.2 Criticality and Risk Assessment

Equipment shall be prioritized according to criticality. The criticality criteria must

be set forth and agreed upon by engineering, operations, maintenance and
safety departments prior to conducting criticality assessment. Systems and
equipment redundancies must also be considered and identified.

An equipment item’s risk rank is determined by the consequence of its failure and
the probability of the failure occurring (Risk=Failure Consequence x Failure
Probability). The criticality of an equipment item is directly related to the
consequence of its failure (according to the criteria set forth in criticality
assessment), while failure probabilities are ranked according to failure
frequencies. Both criticality and failure probability ranks combine to create a risk
rank for the facility under consideration.

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Process Safety Management System

11.3 Maintenance Analysis

Having identified and ranked equipment items by consequence and risk, the next
task is to develop specific inspection and maintenance programs.

Output from this analysis shall include the following:

 Maintenance, inspection and testing tasks and their frequencies for rotating,
electrical and instrument equipment.
 Inspections/test requirements and frequencies for pressure vessels, tanks,
and piping and valves.
 Inspection and test frequencies for relief systems and equipment.
 Identifications of special techniques and methods for inspection and
maintenance. This includes special procedures and predictive technologies
and systems.
 Required spare parts. Purchase order and spare parts specification shall be
reviewed before submitted to the suppliers.
 Expertise and training requirements.

11.4 Implementation

Implementation task during asset operational phase shall involve the following:

1. Developing detailed maintenance and inspection procedures.

2. Creating job plans and work packages and loading them to the MAXIMO
system.
3. Condition based systems implemented (corrosion management, vibration
analysis, thermography, leak monitoring, etc.).
4. Training programs developed and conducted.

11.5 Continuous Improvement

This stage shall involve continuous assessment of equipment performance

during the operational phase through the following:

1. Equipment history captured through repair reports and records.

2. Corrective actions taken based on the results of inspection and maintenance
tasks.
3. Equipment performance monitored. Maintenance task frequencies adjusted
to reflect improvement (or lack of improvement) in reliability.
4. Deficiencies in work procedures and work execution identified and necessary
corrective action taken.

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Petrochemical Industries Co. (K.S.C.)
Process Safety Management System

5. Training records of employees and contractors are kept and evaluated.

6. Risk reassessed and mitigated through adjustment to existing or newly

devised inspection and maintenance programs.

END OF PROCEDURE

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Petrochemical Industries Co. (K.S.C.)
Process Safety Management System

Figure 1: MECHANICAL INTEGRITY PROGRAM PROCESS

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