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Mechanical Integrity

Mechanical Integrity – A Comprehensive Approach

Mechanical Integrity (MI) is a means to minimize the potential for loss of containment of hazardous chemicals. While mechanical integrity is viewed by many in industry to be all about testing and inspection at the core, it is much more comprehensive than that and incorporates all 7 elements of MI that manage asset reliability as the real core of an effective MI program.

An effective MI program relies on solid Asset Strategy Management (ASM). As companies mature, ASM imbeds all 7 elements of MI into management of their assets.

Mechanical Integrity has work processes for each element, the following is an example of the testing and inspection work process which should encompass the following key activities.

Graphic that depicts an example of the testing and inspection work process for Mechanical Integrity

OSHA 1910.110 (j), ABSA AB 512 and DOT PHMSA Gas Transmission Integrity Management has been a key driver in helping industry focus on Asset Integrity Management (AIM) and regulatory compliance. Recent industry incidents and societal views have helped drive an awareness of a need for Risk-Based Mechanical Integrity programs with a focus on Risk-Based Inspection (RBI) and Reliability-Centered Maintenance (RCM). Good engineering practices also advocate for Integrity Operating Windows (IOWs) to address feedstock variability and process upsets.

An effective MI program needs to rely on robust technical standards and competency and training programs. The purpose of MI is to ensure that process equipment and systems are designed, fabricated, installed, maintained, inspected, tested, and replaced to prevent failures, process upsets, and accidental releases.

Table of key Mechanical Integrity elements: Design, Fabricate, Install, Operate, Maintain, Decommission

While effective MI is critical to achieving process safety compliance, maximizing uptime of equipment in operating facilities is key to maximizing profitability. A holistic MI program contributes to an Asset Performance Management (APM) strategy and helps companies leverage data from sensors to predict failures. We help you move beyond traditional, human-intensive reliability engineering to utilizing asset strategy libraries to maximize efficiency and effectiveness.

Quality Assurance (QA) is the key upfront element of an MI program and is performed during the Construction phase of the asset. QA ensures new equipment is designed, fabricated, transported, inspected upon receipt, stored, and properly installed so it will be suitable for the process applications in which it will be used.

After initial startup, the asset enters the Operational phase of its asset lifecycle. The remaining MI program elements are performed during this phase.

  • Maintenance Procedures – Provides the “How” to manage ongoing activities to maintain the ongoing integrity of the equipment.
  • Quality Control – Ensures maintenance materials, spare parts and equipment are suitable for the process application in which they will be used.
  • Equipment Deficiencies Management – Ensures the appropriate corrective actions are completed once equipment deficiencies are identified.
  • Testing and Inspection – Monitor the condition of the equipment to maintain associated damage mechanisms within acceptable limits.
  • Reliability Engineering – Utilizes methodologies to identify and eliminate defects in equipment both before and/or equipment failures.
  • Maintenance Training – All personnel performing maintenance tasks on equipment are trained and competent to perform the work

Lifecycle Concept for PSM Critical Equipment

Table that lists the elements pertaining to the Construction phase (Quality Assurance) and the Operation phase (Mechanical Integrity)

OESuite™ Business Benefits for Mechanical Integrity

Mechanical Integrity Business Benefits graphic

OESuite™ Mobility

Services

Operational Sustainability, LLC® can help companies develop a comprehensive mechanical integrity strategy. It starts with developing MI work processes and accountability structures. Next, an MI gap assessment is conducted to assess the existing MI program. The results of the gap assessment will help identify technical standards that are lacking, along with a strategy for MI data management. Finally, an implementation plan will be created to layout a new MI program.

Graphic: Continuous Lifecycle: Design - Source - Build - Start Up - Operate - Maintain - Decommission

Technical Content

Operational Sustainability, LLC® assists clients with Conduct of Operations by developing business processes, standards, policies, procedures, and field guides. The Operational Sustainability OESuite™ software effectively addresses all aspects of change from an integrated Operations Management System. OS offers 40 Mechanical Integrity technical standards.

Graphic that lists all the Field Guides, Procedures, Standards, and Policies for Mechanical Integrity

Not only does OS offer customizable technical content, we also offer our industry leading OESuite™ software platform with nearly 40 modules. To accelerate the implementation of our software, we offer:

  • Pre-configured Work Processes
  • Best Practices and “To Be” Workflows
  • Canned Reports
  • Dashboards
  • Computer-Based Training (CBT) Modules
  • Protocol
  • Checklists

Our Technical Content will save you thousands of hours, while allowing you to focus on your organization’s core capability.

OESuite™ Integrations / Connectors

OESuite™ offers several modules to underpin a mechanical integrity program.

Key integrations from the MI portfolio include:

  • Inspection Summary reports with work notifications
  • Preventative and Predictive Maintenance within Work Management/CMMS
  • Equipment with the Asset Registry
  • Integrity Operating Windows with data historians
  • Execution of MI with Asset Strategy Management (ASM)
  • Non-Destructive Evaluation data loggers (i.e., Ultrasonic readings)

These integration points also allow for the enablement of robust and unique Key Performance Indicators (KPI) within the OESuite™ platform. OESuite™ is integrated with leading data historians including OSI PI, IP.21 and enterprise asset management systems like SAP PM, and Maximo.

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