Mechanical Integrity Assessments

Are you aligning damage mechanisms with fixed equipment asset strategies? Do you measure both human and program performance? Are you equally concerned about organizational, human, and technical aspects? The MI Assessment addresses these concerns and more as an interdependent assessment of your people, process, and technologies. The result is a path forward that elevates your existing program, minimizes risks of production loss and hazardous chemical release, closes gaps in regulatory compliance, and achieves best practices.
Mechanical Integrity Assessments

What is a Mechanical Integrity Assessment?

The experts at Asset Optimization Consultants ensure that your company meets the highest standards of development, implementation, and maintenance of Mechanical Integrity, including readiness for the National Emphasis Program (NEP) as well as compliance with OSHA requirements.

Our consultants have designed and implemented hundreds of sustainable Mechanical Integrity Programs, which include an MI Assessment. A Mechanical Integrity Assessment is an interdependent assessment of your:

  • People - AOC closely aligns its approach to delivering performance improvement to the Human Performance Improvement (HPI) model from the American Society for Training and Development (ASTD). HPI is a results-based, systematic process that identifies performance problems, analyzes root causes, selects and designs actions, manages interventions in the workplace, measures results, and continually improve performance within an organization.
  • Process - This includes the work process and the procedures as well as Key Performance Indicators (KPI's) to measure the effectiveness of the MI work process.
  • Technology - These are the tools/software used to facilitate the work process.

As a result of a Mechanical Integrity Assessment, you are directed on a path forward that:

  • Elevates your existing MI program
  • Minimizes the risks of production loss and release of hazardous chemicals
  • Closes gaps in regulatory compliance
  • Achieves best practices

How is a Mechanical Integrity Assessment performed?

Our consultants begin with a visit to your plant to build rapport with your staff as well as become familiar with your existing work processes and procedures, level of personnel qualifications and responsibilities, and technologies for tracking and reporting current work processes. Following our initial visit, we provide assessments in these 11 sessions:

Administration and Management

A good Mechanical Integrity System can only be implemented and improved with strong leadership that is supported from the top of the organization. This session addresses the commitment of the site to Mechanical Integrity. Key points include the development and documentation of a mechanical integrity manual and work processes, assignment of responsibilities, employee involvement, compliance audits, and the interaction between other PSM elements.

Documents and Information

Procedures and the control of data play important roles in the implementation of an MI system. The MI system should be based upon a well-prepared set of controlled procedures that describe the objectives to be completed, the manner in which they should be completed, and assignment of responsibilities. In addition, the collection of data should be managed in a manner that makes your data useful and available.

Training

The training session addresses the current training that is performed at the site. Training is a required element to assure that all employees who work in a process that contains hazardous chemicals receive training in process overview, safety, and job tasks. The training program must include a training effectiveness evaluation and an opportunity for retraining when necessary.

Planning and Scheduling

This session addresses the plan, schedule, and tracking of activities related to Mechanical Integrity. Inspections, tests, and preventative maintenance activities must be performed on a scheduled basis, and the correction of deficiencies must be tracked. A deficiency in these areas is defined as a nonconformance that must be corrected now or later. OSHA 1910.119(j) requires the documentation and tracking of deficiencies until they are corrected.

Quality Assurance

The Quality Assurance element is necessary to assure that new projects, new construction, maintenance materials, and spare parts are suitable for their intended use. This session evaluates the effectiveness of the QA/QC functions.

Relief/Vent Systems and Components

This session evaluates the effectiveness of the current system for inspecting and testing pressure-relieving devices, which are part of the pressure-containing envelope. They provide primary protection in the prevention of catastrophic releases of hazardous materials by providing a means for the controlled release of excessive process pressure.

Piping Systems and Components

This session ensures compliance with the standards and requirements issued by the American Petroleum Institute. In the past, few industrial sites had an effective program in place for inspecting and testing piping systems. However, the OSHA regulation has defined piping as part of the process system which must be tested and inspected to assure mechanical integrity.

Pressure Vessels and Storage Tanks

Pressure vessels and storage tanks are specifically addressed in the PSM regulation as part of the pressure-containing envelope. This session ensures compliance with these regulations.

Emergency Shutdown and Control Systems

Process controls provide operating information in order to monitor the conditions within the process that contain process changes in equipment and controls. This session addresses emergency shutdown systems, which provide a way to prevent the development of release conditions and to minimize the effects of a release.

Rotating Equipment

This session ensures regulatory compliance of rotating equipment in "covered" processes are included in the Mechanical Integrity system since they provide primary protection in the prevention of the catastrophic release of highly hazardous materials. The OSHA regulation specifically identifies pumps as covered process equipment, but further clarification from OSHA has confirmed that other rotating machinery such as compressors and turbines are expected to be included in the program as well.

Electrical Systems

OSHA expects electrical systems to be included in a mechanical integrity program because they supply energy to electrical rotating equipment and the critical control systems. With regard to electrical classification, electrical systems are part of the required process safety information. To properly perform this classification, records must be maintained of the inspections and work performed on the electrical systems in the various covered processes. Strengths of the electrical systems test and inspection program will be evaluated as per NFPA 70B and NFPA 110 for inspecting and maintaining emergency power generators.

Related Knowledge

The MI Assessment - Understanding Your Mechanical Integrity Goals

Compliance? | Best Practice? | Risk Reduction? | One Step at a Time? | Capture Personnel Knowledge? | All Of The Above?

Operational Readiness - Ensuring the Transition from Construction to Startup to Operations and Maintenance

Design basis RBI? Why not optimize all your asset families prior to RFSU?

Data Mining, Management, and Migration

Sometimes moving millions of data fields from ten different databases to another seems like trying to get a thousand birds to leave the branches of one tree and land on just the right branches of another.

Production Loss Accounting - Heat Exchanger Bad Actor Analysis

Heat exchanger failures contribute to over $146M in losses for a large refining enterprise.

OSHA Compliance

What do you do when you are on the job for six weeks and you have a toxic leak twice the release of the recent DuPont event? Not to mention the fact that it is only 1992 and OSHA 1910.119 is just getting started...

Time to Value - Asset Integrity Management Delivered, Confidently, Comprehensively and Quickly. An AOC & Intergraph RBI Solution

Delivering knowledge based asset files from the true sources of data - confidently, accurately, electronically, and in half the time.

Implementing RBI in Remote Locations

The importance of understanding risk and the significant value attainable through the implementation of risk based inspection (RBI)

From Fitness for Service to a Reliability-Based Mechanical Integrity Program - A Journey from the Ashes to Sustained Reliability (RMC-10-30)

An upgrader is brought safely back into production a year ahead of expectations, avoiding an opportunity cost exceeding $300 million.

Risk Based Asset Management - Delivering and Sustaining Value Across a Mid-Sized Refining Enterprise (RMC-09-45)

The business case developed for an RBI program - realized benefits and how the on-going value of the program is measured

Related Services

Master Data Management and Data Conversion

Innovative technology that allows quick, efficient extraction of data into a knowledge-centric world

Integrity Operating Window Development

Key parameters and mitigating actions for variables that may dramatically affect the intended design life of your asset

Mechanical Integrity: Development of Procedures, Work Processes, and Human Performance Improvement

A maintenance system designed in which elements work together as a quality system for maximum returns

RAM, RCM, FMEA, FMECA and Bad Actor Analysis

AOC delivers the policies, procedures, work processes, knowledge and actions such as preventive maintenance, predictive maintenance, and condition monitoring tasks.

End-of-Life, Remaining-Life, and Fitness-for-Service Assessments

When evaluation of inspection results suggest that an asset is near its end of useful life, Fitness for Service evaluations can determine if the asset us suitable for continued operation.

Corrosion Control Planning

Achieving zero corrosion-related loss of primary containment in the refining industry.

Reliability Based Asset Management - AIM for all asset families

Asset Integrity Management for all asset families - Rotating, Electrical, Instrumentation, and Fixed Assets

Related Training

RBI/MI Overview

What is Risk Based Inspection?

Equipment Data Collection

What information do we need to collect to support a Mechanical Integrity and/or RBI program?

Damage Mechanism Identification and Review

How do we identify and quantify the damage mechanisms that affect our equipment?

Estimate Risk

How do I estimate risk using the information that I have?

Activity Planning, Execution, and Evaluation

How do I plan and perform inspections and tests?

Manage Changes and Communicate Results

How do I ensure that my MI/RBI program is up to date and communicate to stakeholders?

Risk Based Inspection (RBI) - A Mechanical Integrity Best Practice

What are your goals for RBI? How will you measure your success? How will you sustain that success?

RBI Concepts - Return on Net Assets (RONA)

Asset Integrity Management – how you perform at the plant level affects those goals set at the board room

Value Proposition

Developing the value proposition and business case for an RBI program

Asset Integrity Management Assessments

How important are they?

Calculating the Value Contribution

How does your AI program meet your RONA goals?