Course Material

1.
2.
3.
4.
5.
6.
7.
8.
9.

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

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

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.
2.
3.
4.
5.
6.
7.
8.
9.

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