Mechanical Integrity, Safety & Reliability

Course Introduction

This 5-day course provides a comprehensive understanding of Mechanical Integrity (MI) principles, focusing on ensuring the safety, reliability, and performance of mechanical systems. Participants will learn how to develop and maintain effective MI programs to prevent failures, reduce downtime, and enhance workplace safety. The course covers asset integrity management, risk-based inspections, failure analysis, and compliance with relevant standards and regulations.

Objectives

By the end of this course, participants will:

•     Understand the fundamentals of Mechanical Integrity (MI) and its importance in ensuring safety and reliability.
•     Identify common mechanical system failures and implement preventive measures.
•     Develop and maintain a comprehensive MI program.
•     Apply Risk-Based Inspection (RBI) techniques to prioritize maintenance activities.
•     Ensure compliance with safety regulations and industry standards (e.g., API 580, OSHA).
•     Improve overall equipment reliability and reduce unplanned downtime.

Target Audience

•     Maintenance Engineers
•     Mechanical Engineers
•     Reliability Engineers
•     Plant Supervisors
•     Safety Officers
•     Asset Integrity Managers
•     Operations Personnel involved in equipment reliability and safety

Daily Topics

Day 1: Introduction to Mechanical Integrity

•     Overview of Mechanical Integrity and its role in asset management
•     Key elements of an effective MI program
•     Regulatory requirements and industry standards (OSHA, API)
•     Mechanical system failure types and causes
•     The impact of MI on safety and operational performance

Practical Session: Case study on historical mechanical failures

Day 2: Asset Integrity Management Systems (AIMS)

•     Establishing an Asset Integrity Management System
•     Inspection and testing requirements
•     Identifying critical assets and failure modes
•     Integrity operating windows (IOWs)
•     MI documentation and reporting

Practical Session:Creating a sample asset register and inspection plan

Day 3: Risk-Based Inspection (RBI) and Reliability Techniques

•     Introduction to Risk-Based Inspection (RBI)
•     Conducting risk assessments for mechanical systems
•     Prioritizing inspections and maintenance tasks
•     Reliability-Centered Maintenance (RCM) principles
•     Failure Modes and Effects Analysis (FMEA)

Practical Session:RBI and RCM exercise for critical equipment

Day 4: Failure Analysis and Prevention

•     Identifying and analyzing mechanical failures
•     Root Cause Analysis (RCA) methodology
•     Common failure mechanisms (corrosion, fatigue, creep)
•     Preventive and predictive maintenance strategies
•     Implementing corrective actions to prevent recurrence

Practical Session: Hands-on failure analysis case study

Day 5: Ensuring Safety and Compliance

•     Safety considerations in mechanical integrity programs
•     Compliance with OSHA Process Safety Management (PSM) requirements
•     API standards for pressure vessels, piping, and rotating equipment
•     Developing a safety culture to improve reliability
•     Final assessment and action plan for MI program implementation

Practical Session: Creating an MI action plan for a plant scenario

Assessment:

•     Daily quizzes
•     Practical exercises on MI, RBI, and RCA
•     Final group project: Developing a Mechanical Integrity Plan

Certification: Participants will receive a Certificate in Mechanical Integrity, Safety & Reliability upon successful completion of the course.

For registration, course outline & more information please contact

NAYEL Training Centre 

Tel: +971 4 379 7245 | Mob: +971 50 249 6876 | WhatsApp: +971 50 249 6876

Email:  [email protected]