Mechanical Integrity Quality Assurance

Lesson Objectives  Describe How to Ensure Controls in Place for QA  Describe Standard Record for Inspection and Testing for QA  Describe How to Implement Inspection and Testing for QA  Describe Adequate Records Management for QA

Discussion  The Plant Owner is Responsible for ensuring a System is in Place for QA of New or Modified Equipment.  Vendors and Manufacturers Should be Contractually Bound to Provide for QA  Design – Must be Checked, Certified, and Documented; Controls Must be in Place to Assure Contractor is Qualified and will Follow Good Engineering Practice  Procurement and Fabrication – Manufacturers Must be Qualified to Do the Work by e.g.:  Check of Their Engineering Standards  Check of Prior Experience with Similar Designs  Recommendations from Process Technology Suppliers  Observation of Production Techniques and Results

Discussion (cont’d)  Installation  Receipt Inspection to Include Check Against Procurement Documents  Secured Warehousing and Controlled Release for Installation or Maintenance  QA Punchlists Should be Used e.g. Foundation Installation and Anchor Bolt Pattern Meet Specs., Piping Properly Fabricated, Machinery Properly Installed, etc.  Correction of Deficiencies – Controls to Ensure Documentation and Correction Using RAGAGEP. MOC Process May be Needed if Correction to Original Design Specifications Cannot be Assured  Transfer of Custody – Procedures Need to be in Place to assure Mechanical Integrity During Commissioning and Startup, Concerns Might Include:  Training in Operations Procedures  Curing Refractory in Fired Heaters  Controlling Stress on Startup  Conditioning Catalysts

I&T Records for QA - Must Ensure Equipment Installed Properly and Consistent with Design Specifications and Manufacturer’s Recommendations  Standard I&T Report Information from Previous Module  Inspection of Fabricated Equipment and Package Units for Handling Damage and Missing Parts  Properly oriented bolted and torqued grouted equipment  Machinery, as installed, is properly fabricated assembled, tested, and run-in  Deficiencies Identified and Corrective Action Taken