course material 1.overview of process safety 2.compliance with standards 3.process hazard analysis...

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

6. Mechanical Integrity

Process Safety Management for

Biofuels

This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

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

Losses54%

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 Integrity

OSHA 1910.119(j)

Mechanical Integrity

Program

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

2.Designates equipment included in the program

3.Prioritizes equipment

4.Plans maintenance

Mechanical Integrity

Program

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 Integrity

1. New Plants & Equipment

Mechanical Integrity

2. Equipment Selection

Mechanical Integrity

3. Testing and Planned Maintenance

Mechanical Integrity

4. Equipment Deficiency

Recognized and Generally Accepted Good Engineering

Practice

Mechanical Integrity

5. RAGAGEPs

API

ASME

ISA

RAGAGEPs

Mechanical Integrity

API 650

Mechanical Integrity

ASME

Mechanical Integrity

ISA

Mechanical Integrity

6. Training

Mechanical Integrity

7. Documentation

Mechanical Integrity

8. 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 Integrity

9. Maintenance & Spare Parts

“Replacement in Kind”

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

Mechanical Integrity

Benefits

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

Mechanical Integrity

Benefits

Mechanical Integrity

Benefits

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