FIVE-YEAR MECHANICAL INTEGRITY INSPECTION

ULTRA-SONIC THICKNESS TESTING

PCI provides Ultra-sonic thickness testing of process piping and equipment.  We can determine the current thickness today and provide an estimated remaining life based on the assumed age of the pipe and original thickness.

• Upon the completion of the PROTEXUS Program the annual visual inspections can be performed by PCI or your refrigeration operators.
• The information will already be in the PROTEXUS Program, therefore, you print off the Field Data Collection Form and perform the Visual Inspections.
• Then enter the findings into the PROTEUXS program.
• Generate updated Report Summary
• Make repairs as needed
• REPEAT NEXT YEAR

• In accordance with ASME Section 8, Div 1
• To determine if a vessel is fit to continue operating under the allocated pressure and temperature

PIPING AND INSTRUMENTATION DIAGRAMS

• Using symbology from IIAR’s recommendations or your company’s standards, our field personnel will walk-down and trace the entire ammonia system.
• Then our CAD Technicians will electronically draw using AutoCAD. 
• You will be presented with a Hard-copy of the size you prefer and an electronic copy on CD.

• If your process changes or is expanded our trained field personnel will walk- down and update your existing drawings.
• PCI will convert any old drawings into electronic files using AutoCAD.

• PCI can develop a process flow diagram that can be used for PSM, day-to-day training and maintenance.

• Provide Written Procedures for the Risk Management Plan implementation.
• Determine off-site consequence analysis using EPA”S RMP Comp software
  • (Worst-case scenario and Alternative-case scenarios will be determined).
• Review Maps of affected areas in relation to the worst-case and alternative-case scenarios using Land View software program.
• Provide assistance in developing an Emergency Action Plan including a written procedure, evacuation maps, coordination with the Local Emergency Planning Committee (LEPC) and local Fire Department.
• Provide RMP Submittal using EPA’S RMP Submit software to client for submission.

Develop Process Safety Management Procedures

PCI will provide written PSM procedures for the 14 elements of Process Safety Management.

Employee Participation, Process Safety Information, Process Hazard Analysis, Operating Procedures, Training of Personnel, Contractor’s Safety Program, Pre-Startup Review, Mechanical Integrity, Hot Work Permit, Management of Change, Incident Investigation, Emergency Action Plan and Compliance Audits and Trade Secrets.

Set up Library – Assist in setting up a filing system to maintain all documentation for implementation purposes as well as store Process Safety Information.

Forms - generate all forms applicable for implementation such as Management of Change, Incident Investigation, Pre-Startup Reviews, Operating Procedures format, Contractors Pre-Qualification forms, Hot Work permits, PSM Team Meetings, etc.

In-depth segments for each of the 14 Elements of PSM

• OSHA 1910.119 is a performance based standard.  Therefore, we help our clients through training programs that are easy and doable.
• How to implement and maintain a viable PSM program
• What is recognized and generally accepted good engineering practices (RAGAGEP)?
• How do I persuade other team members to participate?
• How do I prepare for an OSHA or EPA audit?
• What are the Industry recommendations?
• What technology is available?
• What do OSHA and EPA require?
• How do I develop a Mechanical Integrity Program?
• Why is Mechanical Integrity and Preventative Maintenance important to a PSM Program.

Who SHOULD ATTEND?

• Plant Managers
• Environmental/Safety Managers
• Maintenance, Utilities and/or Refrigeration Supervisors
• Refrigeration Operators/Technicians
• Plant Reliability and Project Engineers

PROCESS HAZARD ANALYSIS

PCI has trained PHA Team Leaders to provide new facility PHA’s, Five-Year Revalidation’s or facility modifications.

• The PHA team must include at least one individual that is familiar with the process, and one member of the team must be knowledgeable in the specific analysis methods being used.
• Topics such as the hazards of the process, consequences of failure, and human factors are a few of the table-top discussions during the PHA.
• Findings and recommendations will be documented and presented to the facility within three weeks. The client must set up a schedule for corrective action of the findings with a deadline for completion

OPERATION PROCEUDRES – DEVELOP AND/OR UPDATE EXISTING OPERATING PROCEDURES

• PCI will work with plant personnel to develop written operating procedures for Initial start-up, Normal operations, Emergency Shutdown, Emergency operations, Normal shutdown and Startup following a shutdown. PCI will assure that the Operating Procedures are compliant with OSHA 1910.119 (f).  The Operating procedures will include – Consequences of deviation, and steps to correct  and/or avoid deviation.

OPERATOR TRAINING

• Provide Operator Training in facilities SOP’S and PSM Program
  PCI will work with plant personnel to provide training operating procedures for The Stellar Group individuals that are performing work related task on the ammonia system in the Operating Procedures. The updated training documentation will be placed in the individuals file in the PSM Library.

MECHANICAL INTEGRITY PROGRAM DEVELOPMENT

• Assist in Developing a Preventative Maintenance Program
• Develop Written Inspection and Testing Procedures
• Develop Quality Assurance Procedures

COMPLIANCE AUDITS

• The three year compliance audit will verify that the procedures and practices developed under the PSM standard are adequate and being followed.
• The compliance audit must be conducted by at least one person knowledgeable in the process and a report of the findings of the audit must be developed and documented noting deficiencies that have been corrected.
• The two most recent compliance audit reports must be kept on file.

• PCI provides a pre-audit assessment to determine deficiencies to be corrected prior to an audit.