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Course Material 1.Overview of Process Safety 2.Compliance with Standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures.

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Presentation on theme: "Course Material 1.Overview of Process Safety 2.Compliance with Standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures."— Presentation transcript:

1 Course Material 1.Overview of Process Safety 2.Compliance with Standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures 6.Mechanical Integrity 7.Management of Change 8.Auditing Process Safety Systems 9.Emergency Response Procedures

2 6. Mechanical Integrity Process Safety Management for Biofuels This material was produced under grant SH 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 (j)(4)

3 Catastrophic explosion in Mexico City November 19, 1984

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

5 Mechanical Integrity

6 Mechanical Integrity – Piping Systems

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

8 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

9 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

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

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

23 1. Improved equipment reliability 2. Reduction in equipment failures 3. Improved product consistency 4. Improved maintenance consistency and efficiency Mechanical Integrity Benefits

24 5. Reductions of unplanned maintenance 6. Reduced operating costs 7. Improved spare parts management 8. Improved contractor performance 9. Compliance with government regulations Mechanical Integrity Benefits

25 Mechanical Integrity Benefits

26 Remaining Course Material 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures 6.Mechanical Integrity 7.Management of Change 8.Auditing Process Safety systems 9.Emergency response procedures


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