(1) Written procedures.
(a) The employer must develop, implement, and maintain effective written procedures to ensure the ongoing integrity of process equipment.
(b) The procedures must provide clear instructions for safely performing maintenance activities on process equipment, consistent with the PSI for the process.
(c) The procedures and inspection documents developed under this section must be readily accessible to employees and employee representatives, including affected employees of contractors who are performing work on process equipment, and whose job tasks expose them to process safety hazards.
(2) Inspection and testing.
(a) Inspections and tests must be performed on process equipment using procedures that meet or exceed RAGAGEP.
(b) The frequency of inspections and tests of process equipment must be consistent with:
(i) The applicable manufacturer's recommendations;
(ii) RAGAGEP; or
(iii) Internal practices that are more protective than (b)(i) or (ii) of this subsection.
(c) Inspections and tests must be performed more frequently if necessary, based on the operating experience with the process equipment.
(d) The employer must retain documentation, including certification, where applicable, for each inspection and test that has been performed on process equipment. The documentation, including certification, where applicable, must identify the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other such identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test.
(3) Equipment deficiencies. The employer must correct deficiencies to ensure safe operation of process equipment, including any temporary repairs. Repair methodologies and preventative maintenance must be consistent with RAGAGEP or more protective internal practices.
(4) Quality assurance.
(a) The employer must ensure that all process equipment, at a minimum, complies with the criteria established by the PSI. The employer must ensure that all process equipment is:
(i) Suitable for the process application for which it is or will be used;
(ii) Fabricated from the proper materials of construction; and
(iii) Designed, constructed, installed, maintained, inspected, tested, operated, and replaced in compliance with manufacturer's and other design specifications and all applicable codes and standards.
(b) If the employer installs new process equipment or has existing process equipment for which no RAGAGEP exists, the employer must document and ensure that this equipment is designed, constructed, installed, maintained, inspected, tested and operated in a safe manner.
(c) The employer must perform regularly scheduled checks and inspections as necessary to ensure that the requirements of (a) of this subsection are met.
(d) The employer must ensure that maintenance materials, spare parts and equipment meet design specifications and applicable codes.
(e) The employer must establish a process for evaluating new or updated codes and standards and implementing changes as appropriate to ensure safe operation.
(f) Once an equipment deficiency or failure mechanism is identified, substantially similar equipment in similar service must be evaluated for the same deficiency or failure mechanism.
