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Course Material

This material covers Mechanical Integrity, including its importance, procedures, and benefits for maintaining equipment integrity to prevent accidents. Topics include design, maintenance, and compliance with standards.

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Course Material

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  1. Course Material • Overview of Process Safety • Compliance with Standards • Process Hazard Analysis • Standard Operating Procedures • Safe Work Procedures • Mechanical Integrity • Management of Change • Auditing Process Safety Systems • Emergency Response Procedures

  2. 6. Mechanical Integrity 29 CFR 1910.119 (j)(4) 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.

  3. Catastrophic explosion in Mexico CityNovember 19, 1984

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

  5. Mechanical Integrity

  6. Mechanical Integrity – Piping Systems

  7. OSHA 1910.119(j) “The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment.” Mechanical Integrity

  8. Ensures proper design, fabrication, and installation for new equipment Designates equipment included in the program Prioritizes equipment Plans maintenance Mechanical Integrity Program

  9. Recognizes equipment deficiencies Incorporates recognized and generally accepted good engineering practices Inspects, tests, and performs preventive maintenance Maintains service documentation Mechanical Integrity Program

  10. Mechanical Integrity 1. New Plants & Equipment

  11. Mechanical Integrity 2. Equipment Selection

  12. Mechanical Integrity 3. Testing and Planned Maintenance

  13. Mechanical Integrity 4. Equipment Deficiency

  14. Recognized and Generally Accepted Good Engineering Practice Mechanical Integrity 5. RAGAGEPs

  15. API ASMEISA RAGAGEPs

  16. Mechanical Integrity API 650

  17. Mechanical Integrity ASME

  18. Mechanical Integrity ISA

  19. Mechanical Integrity 6. Training

  20. Mechanical Integrity 7. Documentation

  21. Example of a Mechanical Integrity maintenance training guide Mechanical Integrity 8. Training Mechanically Sealed Pump Reference: “Guidelines for Mechanical Integrity Systems” AIChE/CCPS; Wiley, 2006; Appendix, Chapter 5 Resource Material, “Sample Training Guide”.

  22. “Replacement in Kind” Mechanical Integrity 9. Maintenance & Spare Parts

  23. 1. Improved equipment reliability2. Reduction in equipment failures3. Improved product consistency4. Improved maintenance consistency and efficiency Mechanical Integrity Benefits

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

  25. Mechanical Integrity Benefits

  26. Remaining Course Material • Overview of Process Safety • Compliance with standards • Process Hazard Analysis • Standard Operating Procedures • Safe Work Procedures • Mechanical Integrity • Management of Change • Auditing Process Safety systems • Emergency response procedures

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