Ammonia Plant

1. MECHANICAL
INTEGRITY

2. Objective:
Background:
Mechanical Integrity (MI) program ensures that the integrity of the system
which contains hazardous substances is maintained from the time of initial
installation and throughout the life of the facility.
Target:
Mechanical Integrity targets to eliminate the “breakdown” maintenance of
Safety critical equipments, whose failure could adversely affect the process
safety.

3. Objective:
Purpose:
To ensure the incident free and reliable operation via:
• Equipment Tests and Inspections – Predictive and Preventive maintenance
• Reliability Engineering
• Maintenance, E&I and Quality Control Procedures and the training of
personnel on these procedures (so that the personnel involved in Predictive
and preventive maintenance understand perform the task effectively)

4. PM Plans and Responsibilities
Responsibilities:
To ensure the integrity of the system PM plans are developed. Responsibilities
to develop the PM plans are as follows:
S.No. Equipments Responsibility to Develop PM Plan
1 Stationary Equipments Inspection Section
2 Rotary Equipments Machinery Section
3 Electrical Equipments Electrical Section
4 Instrumentation Instrumentation Section

5. PM Plans and Responsibilities
Operation Responsibilities:
At the time of development of PM plans Operation section Unit Manager (of
relevant plant) will ensure that:
 All safety critical items are included in PM plans.
 Review the timeline of PM plans to ensure that the facility can be handed
over during plant in running condition or not.
 Ensure the compliance of PM plans

6. PM Plans and Responsibilities
Record Keeping:
 Each equipment, system and assembly shall have a master file in which
inspection reports, recommendations and follow-up record is maintained.
 Master file is maintained by the responsible section (i-e Inspection will
keep the record of Stationary equipments, E&I will keep the record of
electrical and instrumentation)
 Record is kept for the life of the equipment

7. Norms of Mechanical Integrity
EHSE Waiver Requirement:
 If a Safety Critical Device / Complete Loop is not tested or a Safety Critical
Equipment not inspected, Executive HSE waiver shall be taken
 Relevant interface which is responsible for non compliance of PM plan will
take the waiver from EHSE. Like Operation will take the waiver from EHSE if
the instrument , equipment cannot be handed over due to any reason.