course material 1.overview of process safety 2.compliance with standards 3.process hazard analysis...
TRANSCRIPT
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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
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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)
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Catastrophic explosion in Mexico CityNovember 19, 1984
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Reference: “Incidents That Define Process Safety”; AIChE/CCPS; Wiley, 2008
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Mechanical Integrity
Losses Due To MI
Program Failure
46%Other
Losses54%
Marsh 100 Largest Chemical, Oil, and Gas Losses
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Mechanical Integrity – Piping Systems
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“The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment.”
Mechanical Integrity
OSHA 1910.119(j)
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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
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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
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Mechanical Integrity
1. New Plants & Equipment
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Mechanical Integrity
2. Equipment Selection
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Mechanical Integrity
3. Testing and Planned Maintenance
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Mechanical Integrity
4. Equipment Deficiency
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Recognized and Generally Accepted Good Engineering
Practice
Mechanical Integrity
5. RAGAGEPs
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API
ASME
ISA
RAGAGEPs
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Mechanical Integrity
API 650
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Mechanical Integrity
ASME
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Mechanical Integrity
ISA
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Mechanical Integrity
6. Training
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Mechanical Integrity
7. Documentation
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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”.
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Mechanical Integrity
9. Maintenance & Spare Parts
“Replacement in Kind”
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1. Improved equipment reliability2. Reduction in equipment failures3. Improved product consistency4. Improved maintenance consistency and efficiency
Mechanical Integrity
Benefits
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5. Reductions of unplanned maintenance 6. Reduced operating costs7. Improved spare parts management8. Improved contractor performance9. Compliance with government regulations
Mechanical Integrity
Benefits
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Mechanical Integrity
Benefits
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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