Mechanical Integrity (MI) is a comprehensive and difficult area for compliance involving a wide range of issues including inspection, testing, preventive and breakdown maintenance, design, materials and equipment selection, fabrication and installation of equipment, RAGAGEP, and skills qualifications.
A complete and effective MI program not only prevents accidents, but also increases productivity and reliability. In addition to compliance with government regulations, an MI program ensures equipment reliability while mitigating down-time for maintenance and equipment failures. Overall, a good MI program will decrease costs and improve product consistency. The MI element of a process safety management (PSM) program is intended to ensure equipment does not fail in a way that causes or affects a release of highly hazardous chemicals. Equipment is the hardware that helps contain the chemicals in the process. MI covers the proper design, fabrication, construction / installation, and operation of equipment throughout the entire process life cycle. Although maintenance is a major part of an MI program, MI is not just maintenance. Other activities are involved such as training and quality assurance.
Mechanical Integrity Audits, Assessments and Program Improvement
Review or audit your MI program and provide recommendations for improvements. If needed, we can help develop, update and implement any improvements.
Mechanical Integrity Program Development
We develop, document and help implement a full MI program for you and address these areas:
Any activity important to an organization must be managed. This requires policies, procedures, work instructions and documentation. Process Risk consultants work with our clients to ensure responsibilities are assigned, authority is given, supervision is provided, resources are made available, and people are held accountable for MI activities.
OSHA defines specific types of equipment that must be included in a MI program. However, this is not intended to be a complete list. Also, while the name of the element implies only mechanical equipment is covered, other equipment which might contribute to a catastrophic release must be included, for example, electrical equipment. Process Risk helps clients determine what equipment should be included in their MI program.
Codes and Standards
There are many industry codes and standards that apply to MI, particularly for design and engineering and preventive maintenance. These must be identified and documented as Recognized and Generally Accepted Good Engineering Practices (RAGAGEP).
Facilities typically employ a combination of breakdown and preventive maintenance. Our consultants help develop appropriate programs that balance these approaches to maintenance.
Written procedures must be developed and implemented for key activities including maintenance. Process Risk works with clients to develop procedures that emphasize usability.
MI personnel must be appropriately trained for the tasks they will perform. Process Risk helps design suitable training programs.
Inspection and Testing
OSHA emphasizes the use of preventive maintenance. Our consultants help develop custom procedures and schedules for inspection and testing of critical process equipment.
Controlling and Managing Deficiencies
Equipment deficiencies found during tests and inspections must be addressed before further use, or in a safe and timely manner when necessary means are taken to assure safe operation. We help our clients determine safe operating limits and to develop procedures for addressing deficiencies.
Quality Assurance (QA)
Process Risk helps our clients develop procedures for quality assurance for equipment procurement, fabrication, installation, repair, and spare parts, maintenance materials and equipment.
Due Diligence Support Dust Hazard Analysis and Management
Dust Hazard Analysis and Management
Emergency Response Programs
Expert Technical Witness - Legal Support Services
Facility Siting & Consequence Modeling
Hierarchy of Controls Analysis (HCA)
Human Factors Review and Analysis
Inherently Safer Technology
Layers of Protection Analysis
LNG Industry Support
Management of Change (MOC) - Process and Organizational Change Assessment
NEP Compliance Support all Industries
Procedure Development and Enhancement
Process Hazard Analysis (PHA)
Project Support and Process Integration
PSM / RM Program Enhancement and Optimization
PSM / RMP Auditing
PSM Program Development
Quantitative Risk Assessment
Risk Management Program (RMP) Support
Safeguards Protection Analysis (SPA)
Safety Instrumented Systems (SIS)
Safety Management Systems
Simultaneous Operations (SIMOPS) Review