Asset Integrity Intelligence July 2016 MECHANICAL INTEGRITY AUDIT CHECKLIST 701 Sawdust Road., Suite #4 office +1.281.397.7075 The Woodlands, TX 77380 fax +1.281.397.9996 Mechanical Integrity Audit Checklist Provided in partnership with Siemens Process Safety Consulting Latest Version - July 2016 Introduction and Disclaimer Thank you to everyone who expressed interest in and attended Inspectioneering’s webinar, Auditing My Mechanical Integrity Program, presented by Mr. Reuben Laurel. This checklist has been provided as a companion piece to the presentation. Great efforts have been made to ensure reporting accuracy and quality. However, Inspectioneering makes no express or implied warranties concerning the information contained herein. Inspectioneering expressly disclaims all warranties, including but not limited to, a warranty of merchantability and warranty of fitness for a particular purpose. The data provided in this checklist is strictly for informational purposes. How to use this checklist If you haven’t done so already, we recommend that you watch a replay of Auditing My Mechanical Integrity Program. To do so, Please visit: http://inspectioneering.com/ landing/auditing-my-mechanical-integrity-program-replay-and-resources You may print a copy of this checklist or use it digitally using a PDF reader. When opened in most common PDF reader applications, you will be able to check/uncheck each of the boxes, type in additional notes for each section, and save your progress. Completed By: Start Date: Completion Date: Inspectioneering, LLC 701 Sawdust Road, Suite No. 4 The Woodlands, TX 77380 www.inspectioneering.com inquiries@inspectioneering.com MI Program Management Yes Does your company and/or site have a documented MI policy? ☐☐ ☐☐ ☐☐ ☐☐ Does your MI program have an administrator or owner? Have MI roles been assigned to specific members of your team? Have you clearly defined the responsibilities associated with each role? No Notes The RACI model is often very helpful when assigning roles and responsibilities: • Responsible: The person who performs the work. • Accountable: The person who is ultimately accountable for the work completed and/or the decisions being made. • Consulted: Any and all people that must be consulted prior to making decisions and/or completion of a task. • Informed: Any and all people that must be informed when a decision is made and/or work is completed. Does your company and/or site have an MI manual which sets out, among other things, the scope and objectives of the MI program? ☐☐ Does your MI program require regular, e.g. monthly, reporting on inspection activities that are due or past due? ☐☐ ☐☐ Are these reports communicated across your entire MI team and followed up on by management and team members? ☐☐ Does your MI program require regular, e.g. quarterly, equipment reports that detail needed repairs and/or replacements? ☐☐ Are these reports communicated across your entire MI team and other appropriate groups, e.g. engineering or maintenance? ☐☐ Does your company and/or facility have a documented policy for addressing equipment deficiencies? ☐☐ Does your MI management team have the appropriate training? MI Audit Checklist Page 2 ! of 13 ! Process Safety Management (PSM) Covered Equipment Does your facility have a master list of all PSM covered equipment? Is this list included in your MI manual? Does your company and/or facility have procedures for evergreening your PSM covered equipment master list? Yes No ☐☐ ☐☐ ☐☐ Do you have procedures for updating your master list when your projects or maintenance teams add, remove, or replace equipment? ☐☐ Has a person been assigned ownership of your master list? ☐☐ If so, who? Notes MI Audit Checklist Page 3 ! of 13 ! Notes Written MI Procedures Yes Does your company and/or facility have documented MI procedures? ☐☐ ☐☐ Are employees aware of these procedures? Are your documented MI procedures easily accessible to all necessary personnel, e.g. MI team members, operations, maintenance, etc.? Do employees know where the procedures are located? Do employees understand the applicability of the procedures to the individual’s role? Does your company and/or facility have documented Process Safety Information (PSI)? Are employees aware of the PSI? Is your PSI easily accessible to all necessary personnel, e.g. MI team members, operations, maintenance, etc.? Do employees know the location of and how to access the PSI? Does your company and/or site have a documented policy for updating and revalidating your MI procedures? Does your company and/or site have document control policies for: MI procedures PSI No ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ Yes No ☐☐ ☐☐ Notes MI Audit Checklist Notes Page 4 ! of 13 ! Notes MI Training Program Yes Does your company conduct Process Overview training for each employee working in a process unit? ☐☐ Does this training include hazards, safety, emergency operations, and safe work practices that are applicable to the employee’s job? ☐☐ Does your company conduct Process Overview refresher training at least every three years? ☐☐ Does your company maintain documentation that details the processes included in the training? ☐☐ Does your company maintain documentation that details: Yes The attendees of each training The date of the training Verification that each employee understood the training Does your company and/or facility have the following requirements defined for inspectors: Training curriculums Certifications Qualifications Does your company and/or facility have the following requirements defined for maintenance technicians: Training curriculums Certifications Qualifications MI Audit Checklist No No Notes Notes ☐☐ ☐☐ ☐☐ Yes No Notes ☐☐ ☐☐ ☐☐ Yes No ☐☐ ☐☐ ☐☐ Page 5 ! of 13 ! Notes MI Training Program Yes No Does your company and/or facility maintain documentation that details the trainings, certifications, and qualifications of each inspector and maintenance technician? ☐☐ Does your company and/or facility have procedures for ensuring that each inspector and maintenance technician renews certifications within required time periods? ☐☐ Does your company and/or facility have procedures for demonstration, testing, and updating the qualifications of each inspector and maintenance technician? ☐☐ Does your company and/or facility have formalized MI program training? ☐☐ Does your company and/or facility have formalized Management of Change (MOC) training? ☐☐ Notes MI Audit Checklist Page 6 ! of 13 ! Notes Inspection and Testing Yes Does your facility have documented inspection schedules? ☐☐ Does your company and/or facility have documented procedures for establishing and updating inspection schedules? ☐☐ Does each piece of equipment covered under PSM have documentation that includes PSI, inspection history, design and other relevant information? ☐☐ For each inspection, is there an inspection folder or package that includes relevant information, e.g. PSI, NDE, drawings, safety, etc.? ☐☐ Are your inspection procedures based on Recognized and Generally Accepted Good Engineering Practices (RAGAGEP), relevant information from equipment manufacturers, and operating experience? ☐☐ Does your company and/or facility have documented inspection and test procedures for: Yes Pressure Vessels Storage Tanks Piping Systems Valves Hoses Relief Systems and Devices Does this include overhaul procedures? Do you have a checklist to ensure inlet and outlet piping are inspected for pluggage? Pumps and Rotating Equipment Does this include preventative maintenance procedures? MI Audit Checklist No No ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ Page 7 ! of 13 ! Notes Notes Inspection and Testing Yes No Does your facility maintain inspection drawings, isometric drawings (ISOs), or sketches that locate TMLs/CMLs? ☐☐ Does your company and/or facility have a process for addressing thickness readings that show growth, high corrosion rates, and thicknesses less than the required minimum? ☐☐ Does your company and/or facility have a documented procedure for addressing negative remaining life? ☐☐ Notes For example, after taking thickness readings and calculating remaining life, it is determined that equipment thickness dropped below minimum design thickness prior to taking the thickness readings. In these cases, is there a procedure for addressing when the equipment should have been inspected in the past and what measures should have been taken, e.g. fitness for services assessment or retire the equipment? ☐☐ Does your company and/or facility have documented procedures for prioritizing maintenance and testing of rotating equipment? ☐☐ Do these procedures account for different severity levels of adverse conditions? ☐☐ Does your company and/or facility have documented inspection and loop check procedures for all instrument loops and functions? ☐☐ Does your company/and or facility have documented procedures for addressing inconsistencies between test set points versus what’s actually found in the field? ☐☐ Has a person been assigned the responsibility of ensuring inconsistencies are addressed? ☐☐ MI Audit Checklist Page 8 ! of 13 ! Inspection and Testing Yes No Does your facility have past due inspections and/or tests for the following equipment types: Pressure Vessels ☐☐ If so, how many? Storage Tanks ☐☐ If so, how many? Piping Systems ☐☐ If so, how many? Valves ☐☐ If so, how many? Hoses ☐☐ If so, how many? Relief Systems and Devices ☐☐ If so, how many? Rotating Equipment ☐☐ If so, how many? Does your company and/or facility have documented procedures for managing inspections and tests that are past due? MI Audit Checklist ☐☐ Page 9 ! of 13 ! Notes Inspection and Testing Yes No Have specific people been assigned the repsonsibility of reviewing and approving: Inspection reports and findings ☐☐ If so, who? Test reports and findings ☐☐ If so, who? Preventative maintenance ☐☐ If so, who? Have these review and approval responsibilities been included in your MI program assignment of responsibilities? ☐☐ Does your company and/or facility have processes in place to ensure the minimum information required by regulators, e.g. OSHA, is included in documentation? ☐☐ Notes MI Audit Checklist Page 10 ! of 13 ! Notes Deficiencies and Repairs Yes No Does your facility have a process for documenting equipment deficiencies, i.e. deficiency tracking list? ☐☐ Are deficiencies tracked to completion? Does your company and/or facility have procedures for removing deficiency recommendations from the tracking list? ☐☐ ☐☐ Does your facility have any reported deficiencies that were not addressed? ☐☐ Are fitness for service (FFS) assessments performed to address deficiencies? ☐☐ If so, how are the FFS assessments documented? Who is responsible for managing, performing, and documenting FFS assessments? Who is responsible for writing the scope of repairs or necessary corrective actions to restore equipment integrity? Is the person or organization responsible for repairs issued a work package with the necessary PSI and other relevant information? ☐☐ Are temporary repairs managed and tracked to permanent repair? ☐☐ Are repairs re-inspected to verify code compliance? ☐☐ Is risk re-assessed on repairs to determine if further monitoring is required or administrative or corrective action is necessary? ☐☐ MI Audit Checklist Page 11 ! of ! 13 Notes Quality Assurance (QA) Yes Does your facility have a documented QA program? ☐☐ Does your company have QA/QC procedures for: Yes Fabrication of new vessels Fabrication of new piping Incoming materials Leftover materials Installation of new equipment Materials identification Relief devices Rotating equipment Instrumentation and controls Is required QA/QC performed during and/or after: Repairs Assembly Installation No No ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ ☐☐ During After ☐ ☐ ☐ ☐ ☐ ☐ Notes MI Audit Checklist Notes Page 12 ! of 13 ! Notes Quality Assurance (QA) Yes No Does your company and/or facility have standard procedures that define the required specifications, documentation, and information when procuring spare parts or replacement equipment? ☐☐ Does your company and/or facility have documented policies for managing obsolete equipment when replacement parts cannot be obtained? ☐☐ Are pressure vessels repaired inside of your facility? ☐☐ Does your company and/or facility have policies or procedures to ensure applicable ASME section (or other applicable codes) compliance? ☐☐ Does your company and/or facility have a documented process for inspecting and certifying vessels built on-site? ☐☐ If so, what is the process? Notes MI Audit Checklist Page 13 ! of 13 ! Notes
