Text For Citation: 02 Item/Group: 003C Hazard: CHEMNEP

29 CFR 1910.119(j)(4)(ii): Inspections and testing procedures performed on process equipment to maintain its mechanical integrity, did not follow recognized and generally accepted good engineering practices: Facility: Employer did not follow good engineering practices for the following inspections and tests: a) The mechanical integrity program did not include procedures for the inspection and testing of pressure vessels and heat exchangers that followed good engineering practices. Good engineering practices for the inspection and testing of pressure vessels and heat exchangers include: 1. Weekly detailed inspection of external surface or of the insulation applied to the external surface performed by system operating personnel when equipment is operational. 2. Annual inspection of external surface or of the insulation applied to the external surface performed by persons other than normal system operators. 3. Weekly or at regular intervals drain oil from all oil drain points. 4. Annually test automatic controls such as head pressure controls for correct operation. 5. Full independent inspection by competent person every 5 years on annual inspection requirements. When appropriate, perform additional techniques to check for cracks and flaws and thickness measurements by using dyes, ultrasonic measurements, and radiography. b) The mechanical integrity program did not include procedures for the inspection and testing of ammonia supply pumps that followed good engineering practices. Good engineering practices for the inspection and testing of ammonia supply pumps include: 1. Isolate, vent, and defrost ammonia pumps at least monthly. c) The mechanical integrity program did not include procedures for the inspection and testing of shut-off valves and control valves that followed good engineering practices. Good engineering practices for the inspection and testing of shut-off valves and control valves include: 1. Visually inspect shut-off valves on machinery when operational inspection of such machinery is conducted. 2. Every 6 months, inspect condition of stem and gland seals on shut-off valves with exposed stems and clean and re-grease stem. 3. Externally inspect shut-off valves annually. 4. Test shut-off valves every 5 years for function.5. Annually test automatic control valves for correct function. d) The mechanical integrity program did not include procedures for the inspection and testing of pressure relief devices that followed good engineering practices. Good engineering practices for the inspection and testing of pressure relief devices include: 1. Visually inspect pressure relief devices annually for corrosion or accumulation of scale and for leaks. 2. Annually inspect vent lines. e) The mechanical integrity program did not include procedures for the inspection and testing of sensing devices such as pressure, temperature, or level operated switches or controls, pressure gauges, ammonia vapor detectors that followed good engineering practices. Good engineering practices for the inspection and testing of sensing devices include: 1. Inspect, test, and calibrate sensing devices such as pressure, temperature, or level operated switches or controls, pressure gauges, ammonia vapor detectors as per manufacturer's recommendations. 2. Annually test safety cutouts. f) The mechanical integrity program did not include procedures for the inspection and testing of piping that followed good engineering practices. Good engineering practices for the inspection and testing of piping include: 1. Annually inspect uninsulated piping. 2. Annually conduct external inspection of insulated piping and supports.