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Article history:
Received 23 May 2007
Received in revised form
9 April 2008
Accepted 23 April 2008
Available online 6 May 2008
The mechanical integrity (MI) of equipment has been controlled at all industrial facilities for many
decades. Control methods and intervals are regulated by laws or codes and best practices. In European
countries, the legislations implementing the Seveso Directives on the control of major accident hazards
require the owner of establishments where hazardous chemicals are handled, to implement a safety
management system (SMS). MI controls should be an integral part of the SMS. At large establishments
this goal is achieved by adopting the RBI method, but in small-sized establishments with a limited
budget and scanty personnel, a heuristic approach is more suitable. This paper demonstrates the
feasibility and advantages of integrating SMS and MI by means of a simple method that includes a few
basic concepts of RBI without additional costs for operator. This method, supported by a software tool, is
resilient as it functions effectively in spite of eventual budget reductions and personnel turnover. The
results of MI controls can also be exploited to monitor equipment condition and demonstrate the
adequacy of technical systems to the Competent Authorities (CA). Furthermore, the SMS can capture
knowledge resulting from MI experience and exploit it for a better understanding of risk.
& 2008 Elsevier Ltd. All rights reserved.
Keywords:
Mechanical integrity
Safety management system
Risk-based inspection
Major accident hazard
1. Introduction
In developed countries, legislation on the control of major
accident hazards, such as the so-called Seveso Directives that have
been in force in the European Union for 25 years, has contributed
signicantly to reducing the accident rate. In industrial establishments, sound risk analysis methods, sound safety management
systems (SMS) and emergency plans have been introduced by all
major hazard legislations and have had a positive effect on the
overall safety level. Unfortunately, many accidents involving
hazardous chemicals are still reported at small-sized establishments, as well as at the storage units of large plants, which are
usually considered much simpler than process units. Major hazard
legislations do not discriminate small and large establishments,
but only lower-tier and upper-tier on the basis of hazardous
materials quantities. In small sized establishments, organization,
including SMS, may be weak and risk may be underestimated.
Cultural and social issues affecting SMS have to be carefully
considered. At small-sized industrial establishments, personnel
have a much lower cultural prole than workers employed at
facilities owned by major companies, who hire more qualied
staff, provide good training and have permanent education
Corresponding author. Tel.: +39 6 94181 223; fax: +39 6 94181 225.
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vessels
(1a)
pipes
(1b)
or
PD P m D
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Table 1
Hazard ranking based on DOW Fire and Explosion index
DOW F&E index
Hazard ranking
060
6196
97127
128158
4159
1Low
2Moderate
3High
4Very high
5Extremely high
(2)
415
Fig. 1. The look-up table that associates risk ranking and IF.
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6. Conclusions
A stronger link between SMS and MI control systems should be
encouraged by the CA. Inspections performed under the SMS in
the framework of major hazard legislation, primarily consider
issues such as safety policy, procedures, personnel, training and
emergency planning, while integrity inspections consider safety
only from a technical point of view. Integrity controls are
widespread, but not systematic, as they are performed by different
experts and by different bodies at different times. Their integration into the SMS is very useful, does not entail additional costs or
higher organizational models and allows owners to exploit
integrity control results to manage overall safety. During inspections on the SMS, the dutyholder could use a system such as PELM
both to demonstrate that integrity control management is
adequate and to give inspectors information for a general
understanding of the current MI conditions.
Economic conditions could lead to reductions in the number of
employees and changes in corporate structures. Cuts in staff could
lead to reduced safety communications, increased stress, less time
for internal inspections and loss of knowledge. The SMS should be
resilient enough to survive these events. PELM is a resilient
implementation of the MI management system, as it can survive
even if the budget is cut. In this case the focus will be on the
mandatory inspections and on critical components, but an
accurate management of inspection data, at no extra cost, will
anyway ensure a reasonable safety level.
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