Course 6: Mechanical Integrity

Day 1 (8:00 a.m. to 5:00 p.m.)

• Learning objectives and goals for mechanical integrity (MI)
  • Motivations for mechanical integrity
    • Regulations, standards, and interpretations
    • Relationship to Reliability programs
• Designing a mechanical integrity program
  • Minimal MI program only for compliance?
  • Fully integrated reliability program?
  • Something in-between?
  • Workshop: Deciding in detail what you need your MI program to
    address (this sets the basis for later workshops and discussion)
• Developing a mechanical integrity program
  • Equipment identification and related issues
    • List of critical equipment
    • Types of MI activities (reactive, proactive, preventive, predictive)
    • Choosing the right task type and choosing the specific task
    • Determining the right frequency for the task (condition or time dependent)
    • Workshop: Starting the development of an inspection, test, and preventive
      maintenance (ITPM) plan
• Developing a mechanical integrity program (continued)
  • Personnel focus
    • Procedures
    • Training
    • Workshop: Completing the development of an IPTM plan by
      identifying written procedures and training needs for your
      mechanical integrity program

Day 2 (8:00 a.m. to 3:30 p.m.)

• Developing a mechanical integrity program (continued)
  • Management systems required and related issues
    • Quality assurance
    • Equipment deficiency resolution
    • Root cause analysis
    • Management of change
    • Workshop: Identifying gaps in your quality assurance plan and
      identifying additional needs for procedures and training
• Implementing/Maintaining a mechanical integrity program
  • Review of detailed checklist for implementing an MI/reliability system
  • Documenting and managing data/results, computer systems and other
    equipment files
  • Workshop: Customizing the detailed implementation checklist to
    your specific needs (optional)
• Roles and Responsibilities for MI
• Workshop: Identifying roles and responsibilities for your MI program
• Key performance indicators for MI and continual improvement of a mechanical integrity program
• Optional Exam

William G. (Bill) Bridges will be the instructor for this course. He has taught this course many times over the past 15+ years.

Bill is President of the Process Improvement Institute (PII). He has over 30 years of experience, including more than 20 in senior management and senior PSM advisory roles. He is considered one of the leading authorities on process safety engineering, risk management, and human error prevention. He has a Bachelor and Master’s degree in Chemical Engineering from the University of Akron (USA) and he has over 14 years of hands-on chemical industry experience in process operation, process engineering, process and product development, management and safety evaluation, and operations management. He holds 10 US patents, several of which are for products and processes that are in full, profitable production today. One factor that makes Mr. Bridges such a sought after consultant and instructor is his wealth of hands-on experience in chemical processing and in implementing PSM in the chemical industry. His last position in the chemical industry was as a chemical plant manager.

Bill has helped many companies in the petroleum, petrochemical, plastic and chemical process industries develop, implement and assess PSM and risk management programs. These programs include consideration of human factors to prevent human error. Bill has written several articles on “how to” prevent human error and how to implement PSM. He serves on the planning committee of AIChE for international conferences on process safety. Bill has taught PSM related courses, including process hazard analysis/HAZOP leadership, incident investigation/RCA, and management of change (MOC) since 1987. He is an instructor for several different courses for PII, and also lectures in American Institute of Chemical Engineers (AIChE) and he teaches through ASSE-MEC and GPCA in the Middle East. He has trained more than 5000 in PSM-related and risk analysis-related topics.

Paul S. Casarez is also an instructor for this course. He has taught this course many times over the past 10+ years.

Paul has over 27 years of experience in process engineering; production and maintenance management; HSE and risk-based safety management. He has facilitated, managed, developed and/or implemented policy and procedures covering every aspect of Risk Based Process Safety. Paul’s process safety experience covers highly toxic, flammable, explosive and highly reactive/unstable chemicals and chemical processes. He has extensive experience in large, intermediate and small (micro) processes along with continuous, batch, and lab operations.

Paul has a B.S in Chemical Engineering from Michigan Technological University.

To find out more about this course or to check into having this course taught at your site, contact Mr. Bridges at 1.865.675.3458 or by e-mail at wbridges@p-i-i-i.com.