OSHA 1910.119(j) MI COMPLIANT
Mechanic Training Program
4 progressive levels. 34 modules. 10 equipment categories. From craft fundamentals to advanced diagnostics — built on API, ASME, and RAGAGEP standards your equipment actually references.
Curriculum Overview
Each level builds on the previous. Progress from hand tool safety to advanced failure analysis and root cause investigation.
1
Craft Fundamentals
Week 1-2 | 8 Modules | ~40 hours
M1.1
Shop Safety & Tool Qualification
Hand tools, power tools, inspection, and safe use in refinery environments
M1.2
Technical Drawing & P&ID Reading
Blueprint reading, assembly drawings, ISA symbology, schematic interpretation
M1.3
Measurement & Precision Tools
Micrometers, dial indicators, feeler gauges, laser alignment, proper use
M1.4
Bolting & Torque Standards
Bolt grades, torque values, sequence patterns, joint integrity under process conditions
M1.5
Gasket Selection & Flange Integrity
Gasket materials, seating stress, ASME B16.20, hot bolting restrictions
M1.6
Rigging & Lifting Safety
Sling inspection, load calculations, rigging plans, crane coordination
M1.7
Confined Space Entry for Mechanics
Permit procedures, atmosphere testing, rescue plans, equipment isolation
M1.8
LOTO for Authorized Mechanics
Energy isolation procedures, de-energization verification, complex LOTO plans
2
Equipment Fundamentals
Week 3-8 | 9 Modules | ~80 hours
M2.1
Centrifugal Pump Mechanics
Impeller types, wear rings, mechanical seals, alignment, API 610 requirements
M2.2
Reciprocating Compressor Overhaul
Valve inspection, piston ring replacement, cylinder reconditioning, API 618
M2.3
Centrifugal Compressor Maintenance
Rotor dynamics, bearing types, seal systems, vibration analysis basics, API 617
M2.4
Control Valve Repair & Calibration
Actuator types, trim replacement, leak testing, positioner calibration
M2.5
Heat Exchanger Maintenance
Bundle pulling, tube plugging, hydroblasting, re-tubing, eddy current testing
M2.6
Fired Heater Inspection & Repair
Tube inspection, refractory repair, burner maintenance, API 560
M2.7
Pressure Vessel Inspection
Visual inspection, NDE methods, nozzle condition, API 510 inspector coordination
M2.8
Piping & Pipeline Inspection
Corrosion under insulation, thickness measurement, API 570 coordination
M2.9
Storage Tank Maintenance
Floor scanning, annular inspection, roof repairs, API 653
3
Advanced Diagnostics
Month 3-6 | 12 Modules | ~120 hours
M3.1
Vibration Analysis Basics
Frequency analysis, imbalance vs. misalignment vs. bearing defects
M3.2
Laser Alignment Certification
Soft foot, thermal growth compensation, angular/offset correction
M3.3
Infrared Thermography for Mechanics
Hot bearing identification, exchanger fouling, electrical equipment inspection
M3.4
Oil Analysis & Lubrication
Sample collection, viscosity, wear metals, contamination, ISO cleanliness codes
M3.5
Corrosion Mechanisms in Refineries
H2S corrosion, sulfidation, HIC, SCC, HTHA — API 571 damage mechanisms
M3.6
NDE Methods for Mechanics
UT thickness, MT, PT, RT interpretation basics — when to call the inspector
M3.7
Relief Device Testing & Inspection
PRV inspection, test procedures, seat leak, API 576
M3.8
Seal Systems & Barrier Fluids
Plan 11-75 seal flush plans, barrier fluid selection, API 682
M3.9
Turnaround Planning for Mechanics
Work scope development, tie-in points, scaffolding, TECO checklists
M3.10
Hot Work in Hazardous Areas
Gas testing, fire watch, standby, permit issuance in classified areas
M3.11
Instrumentation Basics for Mechanics
Reading transmitters, understanding control loops, coordinating with I&E
M3.12
Welding Procedures & PWHT
WPS/PQR basics, preheat requirements, ASME B31.3, post-weld treatment
4
Failure Analysis & RCA
Month 6-12 | 5 Modules | ~60 hours
M4.1
Failure Analysis Methodology
5-Why, fault tree, metallurgical evidence interpretation
M4.2
Case Studies: Pump Failures
10 real refinery pump failure cases with documented root causes and fixes
M4.3
Case Studies: Compressor Failures
8 real compressor failures including surge events and bearing failures
M4.4
Mechanical Integrity Program Overview
OSHA 1910.119(j) requirements, inspection intervals, MI documentation
M4.5
Writing Work Orders & Maintenance History
Documenting maintenance for MI records, failure descriptions, corrective actions
Equipment Categories Covered
Rotating Equipment
Centrifugal & reciprocating pumps, compressors, fans, blowers
Heat Transfer
Shell & tube, air coolers, fired heaters, process furnaces
Pressure Vessels
Reactors, drums, towers, separators
Piping Systems
Process lines, utility lines, underground piping
Valves & Actuators
Control valves, manual valves, relief devices
Storage Tanks
Atmospheric, floating roof, cone roof tanks
Electrical Equipment
Motors, transformers, MCC, switchgear basics
Instrumentation
Transmitters, analyzers, control loops
Flare & Relief Systems
PRVs, rupture disks, flare tips, knockout drums
Mechanical Seals
Single, double, tandem seals, barrier fluid systems
RAGAGEP Standards Referenced
Every mechanic module references the specific industry standards that govern that equipment type — satisfying OSHA’s RAGAGEP requirement for Mechanical Integrity training.
| Standard | Equipment | Key Topics Covered |
|---|---|---|
| API 510 | Pressure Vessels | Inspection intervals, minimum thickness, repair procedures |
| API 570 | Piping | Inspection planning, corrosion loops, thickness monitoring |
| API 653 | Storage Tanks | Floor inspection, shell assessment, fitness for service |
| API 571 | All | Damage mechanisms: corrosion, cracking, high-temp, mechanical |
| API 576 | Relief Devices | Inspection, testing, repair of PRVs and rupture disks |
| API 610 | Centrifugal Pumps | Performance, seal systems, bearing housing, nozzle loads |
| API 617 | Centrifugal Compressors | Rotor dynamics, lube system, surge protection |
| API 618 | Reciprocating Compressors | Valve design, cylinder sizing, pulsation control |
| API 660 | Heat Exchangers | Design requirements, maintenance procedures |
| API 682 | Mechanical Seals | Seal flush plans, seal selection, system design |
| ASME B31.3 | Process Piping | Welding, PWHT, pressure testing requirements |
| ASME B31.4 | Liquid Pipeline | Design, construction, inspection requirements |
| ASME Section VIII | Pressure Vessels | Design basis, repair/alteration requirements |
| ASME Section IX | Welding | WPS, PQR, welder qualification |
| NFPA 70 (NEC) | Electrical | Classified area requirements for mechanical work |
| NFPA 72 | Fire Alarm | Detector placement near hot work locations |
| OSHA 1910.147 | All | LOTO procedures for all equipment types |
OSHA 1910.119(j) Mechanical Integrity Compliance
OSHA’s MI element requires training for maintenance personnel on applicable manufacturing procedures, applicable codes and standards, and applicable equipment deficiencies.
- Manufacturing Procedures — Every module includes the facility’s documented maintenance procedures for that equipment type
- Applicable Codes & Standards — Module content explicitly references and explains requirements from API, ASME, NFPA standards that apply to each equipment category
- Deficiency Recognition — Modules include training on recognizing, documenting, and reporting equipment deficiencies through the work order system
- Documentation — Completion records generated for every module, meeting OSHA’s documentation requirements for MI training
Pricing
Transparent pricing. No per-seat licensing.
Single Module
$500
One mechanic training module with assessment and documentation
- AI-generated content for your specific equipment
- OSHA-compliant completion record
- Instructor guide included
Complete Mechanic Program
$10,000
Full 4-level curriculum — 34 modules, all equipment categories
- All Level 1-4 modules
- All 10 equipment category modules
- RAGAGEP standards reference library
- OSHA audit-ready MI documentation
Custom Equipment Package
$1,500
Training for your specific equipment make/model/serial
- Equipment-specific content
- Manufacturer procedure integration
- Custom assessment questions
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