Section 5110.8 - Mechanical Integrity(a) Written procedures. The owner or operator shall develop, implement, and maintain effective written procedures to ensure the ongoing integrity of process equipment. (1) The procedures shall provide clear instructions for safely conducting maintenance activities on process equipment, consistent with the Process Safety Information.(2) The procedures and inspection documents developed under this subsection shall be readily accessible to employees and employee representatives pursuant to section 5110.13.(b) Inspection and testing. (1) Inspections and tests shall be performed on process equipment, using procedures that meet or exceed recognized and generally accepted good engineering practices (RAGAGEP).(2) The frequency of inspections and tests of process equipment shall be consistent with (1) the applicable manufacturers' recommendations, (2) RAGAGEP, or (3) internal practices that are more protective than (1) or (2). Inspections and tests shall be conducted more frequently if necessary, based on the operating experience with the process equipment.(3) The owner or operator shall retain a certification record to document that each inspection and test has been performed in accordance with this subsection. The certification record shall identify the date of the inspection; the name of the person who performed the inspection or test; a description of the inspection or test performed; the results of the inspection or test; and the serial number or other identifier of the equipment on which the inspection or test was performed.(c) Equipment deficiencies. The owner or operator shall correct deficiencies to ensure safe operation of process equipment. Repair methodologies shall be consistent with RAGAGEP or more protective internal practices.(d) Quality assurance. (1) The owner or operator shall ensure that all process equipment at a minimum complies with the criteria established in subsection 5110.3(d). In meeting this requirement, the owner or operator shall ensure that all process equipment is:(1) suitable for the process application for which it is or will be used;(2) fabricated from the proper materials of construction;(3) designed, constructed, installed, maintained, inspected, tested, operated and replaced in compliance with the manufacturer's and any other design specifications and all applicable codes and standards.(2) If the owner or operator installs new process equipment or has existing process equipment for which no RAGAGEP exists, the owner or operator shall ensure and document that these are designed, built, installed, maintained, inspected, tested and operated in a safe manner.(3) The owner or operator shall conduct regularly scheduled checks and inspections as necessary to ensure that the requirements of paragraph (1) are met.(4) The owner or operator shall ensure that maintenance materials, spare parts and equipment meet design specifications and applicable codes.(5) The owner or operator shall establish a process for evaluating new or updated equipment codes and standards and implementing changes as appropriate to ensure safe operation.(e) Damage Mechanism Review (1) The owner or operator shall complete a Damage Mechanism Review (DMR) for each process for which a damage mechanism exists. Where no DMR is performed, the owner or operator shall document the rationale for the determination that no damage mechanism exists. The owner or operator shall determine and document the priority order for conducting the DMR based on process operating history, PHA schedule and inspection records. No less than 50 percent of the initial DMRs shall be completed within three (3) years of the effective date of this Article, and the remainder within five (5) years of the effective date of this Article. If the owner or operator has conducted and documented a DMR for a process unit within five (5) years prior to the effective date of this section, and that DMR includes the elements identified in paragraph (e)(8), that DMR may be used to satisfy the owner or operator's obligation to complete an initial DMR under this paragraph.(2) A DMR shall be updated at least once every five (5) years consistent with the requirements of this section.(3) A DMR shall be reviewed as part of a major change on a process for which a damage mechanism exists, prior to approval of the change. If a major change may introduce a damage mechanism, a DMR shall be conducted, prior to approval of the change. As part of an incident investigation pursuant to section 5110.12, where a damage mechanism is identified as a contributing factor, the owner or operator shall review the most recent DMR(s) that are relevant to the investigation. If a DMR has not been performed on the processes that are relevant to the investigation, the owner or operator shall conduct and complete a DMR prior to implementation of corrective actions pursuant to section 5110.19(d) and (e).(4) The DMR for a process unit shall be available to the team performing a PHA for that process unit.(5) The DMR shall be performed by a team with expertise in engineering, operation of the processes under review, equipment and pipe inspection, and damage and failure mechanisms. The team shall also include one member knowledgeable in the specific DMR method being used. The owner or operator shall provide for employee participation in this process, pursuant to section 5110.13.(6) The DMR for each process shall include: (A) Assessment of Process Flow Diagrams (PFDs);(B) Identification of all potential damage mechanisms pursuant to subsection (e)(7) below;(C) Determination that the materials of construction are appropriate for their application and are resistant to potential damage mechanisms;(D) A discussion of the conditions that cause the damage mechanism and how rapidly the damage may progress;(E) Methods to prevent or mitigate damage;(F) Review of operating parameters to identify operating conditions that could accelerate damage or that could minimize or eliminate damage;(7) For purposes of this section, damage mechanisms include, but are not limited to: (A) Mechanical loading failures, such as ductile fracture, brittle fracture, mechanical fatigue, and buckling;(B) Erosion, such as abrasive wear, adhesive wear, and fretting;(C) Corrosion, such as uniform corrosion, localized corrosion, and pitting;(D) Thermal-related failures, such as creep, metallurgical transformation, and thermal fatigue;(E) Cracking, such as stress-corrosion cracking; and(F) Embrittlement, such as high-temperature hydrogen attack.(8) DMRs shall include an assessment of previous experience with the process including the inspection history and all damage mechanism data; a review of industry-wide experience with the process; and applicable standards, codes and practices.(9) At the conclusion of the analysis, the team shall prepare a written DMR report that includes: (A) The process unit(s) reviewed;(B) Damage mechanisms analyzed;(C) Results of the analyses conducted according to subsection (e)(7) above;(D) Recommendations for temporary mitigation;(E) Recommendations for prevention.(10) The report shall be provided to and, upon request, reviewed with all operating, maintenance, and other personnel, whose work assignments are within the process unit covered in the DMR.(11) The owner or operator shall follow the corrective action work process documented in subsections 5110.19(d) and (e) when resolving the DMR team's findings and recommendations, determining corrective action for implementation, tracking to completion, and documentation of closeout.(12) DMR reports shall be retained for the life of the process unit.Cal. Code Regs. Tit. 19, § 5110.8
Note: Authority cited: Section 8585, Government Code; and Sections 25531 and 25534.05, Health and Safety Code. Reference: Section 8585, Government Code; Section 25531, Health and Safety Code; and Section 68.73, Part 68, Title 40, Code of Federal Regulations.
1. Change without regulatory effect renumbering section 2762.5 to new section 5110.8, including amendment of subsections (a)(2), (d)(1), (e)(3), (e)(5) and (e)(11), filed 3-6-2024 (Register 2024, No. 10).