06 biofuels mechanical integrity

8/10/2019 06 Biofuels Mechanical Integrity

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Course Material

1. Overview of Process Safety

2. Compliance with Standards

3. Process Hazard Analysis4. Standard Operating Procedures

5. Safe Work Procedures

6. Mechanical Integrity

7. Management of Change8. Auditing Process Safety Systems

9. Emergency Response Procedures


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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 City

November 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 MIProgramFailure

46%Other

Losses54%

Marsh 100 Largest Chemical, Oil, and Gas

Losses


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Piping Systems


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The employer shall establish andimplement written procedures to

maintain the on-going integrity of

process equipment.


OSHA 1910.119(j)


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Program

1.Ensures proper design, fabrication, and

installation for new equipment2.Designates equipment included in the program

3.Prioritizes equipment

4.Plans maintenance


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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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1. New Plants & Equipment


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2. Equipment Selection


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3. Testing and Planned

Maintenance


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4. Equipment Deficiency


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Recognized and GenerallyAccepted Good Engineering

Practice


5. RAGAGEPs


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APIASME

ISA

RAGAGEPs


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API 650


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ASME


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ISA


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6. Training


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7. Documentation


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8. Training

Example of a Mechanical Integrity maintenance training

guide

Mechanically Sealed Pump

Reference: Guidelines for Mechanical Integrity SystemsAIChE/CCPS; Wiley, 2006; Appendix, Chapter 5 Resource Material, Sample Training Guide.
http://localhost/var/www/apps/conversion/tmp/scratch_6/Sample%20Training%20Guide_ABC%20Biofuels.doc


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9. Maintenance & Spare Parts

Replacement in Kind


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1. Improved equipment reliability

2. Reduction in equipment failures3. Improved product consistency

4. Improved maintenance consistency and

efficiency


Benefits


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5. Reductions of unplanned maintenance

6. Reduced operating costs7. Improved spare parts management

8. Improved contractor performance

9. Compliance with government regulations


Benefits


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Benefits


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Remaining Course

Material1. Overview of Process Safety

2. Compliance with standards

3. Process Hazard Analysis

4. Standard Operating Procedures

5. Safe Work Procedures


7. Management of Change8. Auditing Process Safety systems

9. Emergency response procedures

06 biofuels mechanical integrity

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