Course Material1. Overview of Process Safety2. Compliance with Standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe Work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety Systems9. Emergency Response Procedures

6. Mechanical Integrity

Process Safety Management for

Biofuels

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29 CFR 1910.119 (j)(4)

Catastrophic explosion in Mexico CityNovember 19, 1984

Reference: “Incidents That Define Process Safety”; AIChE/CCPS; Wiley, 2008

Mechanical Integrity

Losses Due To MI

Program Failure

46%Other Losses

54%

Marsh 100 Largest Chemical, Oil, and Gas Losses

Mechanical Integrity – Piping Systems

“The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment.”

Mechanical IntegrityOSHA 1910.119(j)

Mechanical IntegrityProgram

1.Ensures proper design, fabrication, and installation for new equipment

2.Designates equipment included in the program

3.Prioritizes equipment

4.Plans maintenance

Mechanical IntegrityProgram

5.Recognizes equipment deficiencies

6. Incorporates recognized and generally accepted good engineering practices

7. Inspects, tests, and performs preventive maintenance

8.Maintains service documentation

Mechanical Integrity1. New Plants & Equipment

Mechanical Integrity

2. Equipment Selection

Mechanical Integrity3. Testing and Planned

Maintenance

Mechanical Integrity4. Equipment Deficiency

Recognized and Generally Accepted Good Engineering

Practice

Mechanical Integrity5. RAGAGEPs

API

ASME

ISA

RAGAGEPs

Mechanical IntegrityAPI 650

Mechanical IntegrityASME

Mechanical IntegrityISA

Mechanical Integrity6. Training

Mechanical Integrity7. Documentation

Mechanical Integrity8. Training

Example of a Mechanical Integrity maintenance training guide

Mechanically Sealed PumpReference: “Guidelines for Mechanical Integrity Systems”AIChE/CCPS; Wiley, 2006; Appendix, Chapter 5 Resource Material, “Sample Training Guide”.

Mechanical Integrity9. Maintenance & Spare Parts

“Replacement in Kind”

1. Improved equipment reliability2. Reduction in equipment failures3. Improved product consistency4. Improved maintenance consistency and efficiency

Mechanical IntegrityBenefits

5. Reductions of unplanned maintenance 6. Reduced operating costs7. Improved spare parts management8. Improved contractor performance9. Compliance with government regulations

Mechanical IntegrityBenefits

Mechanical IntegrityBenefits

Remaining Course Material

1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe Work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety systems9. Emergency response procedures