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
 Process Safety
Management for
Biofuels

6. Mechanical Integrity
29 CFR 1910.119 (j)(4)
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.
Catastrophic explosion in Mexico City
November 19, 1984
Reference: Incidents That Define Process Safety; AIChE/CCPS; Wiley, 2008
 Mechanical Integrity

Marsh 100 Largest Chemical, Oil, and Gas

Losses
Losses Due
To MI
Program
Other Failure
Losses 46%
54%
Mechanical Integrity
Piping Systems
 Mechanical Integrity
OSHA 1910.119(j)

The employer shall establish and

implement written procedures to
maintain the on-going integrity of
process equipment.
 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
 Mechanical Integrity
5. RAGAGEPs

Recognized and Generally

Accepted Good Engineering
Practice
 RAGAGEPs

API
ASME
ISA
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 Pump

Reference: 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
 Mechanical Integrity
Benefits

1. Improved equipment reliability

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

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
 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