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Mechanical Integrity


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.



Services Offered

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:

Management System

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.

Covered Equipment

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). 

Maintenance Tasks

Facilities typically employ a combination of breakdown and preventive maintenance. Our consultants help develop appropriate programs that balance these approaches to maintenance.

MI Procedures

Written procedures must be developed and implemented for key activities including maintenance. Process Risk works with clients to develop procedures that emphasize usability.

MI Training

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.