Mechanical integrity (MI) is a process for managing critical equipment to ensure proper design, installation, maintenance, and inspection over the service life. A good mechanical integrity program will take into account the likely modes of corrosion and likeliness of each form. Then an optimized inspection and testing program is developed, along with written procedures and training programs. Properly implemented, MI can drastically reduce maintenance and lost operating costs, while improving safety throughout the facility.
What is a Mechanical Integrity Program?
MI is perhaps the most important part of a comprehensive Process Safety Management (PSM) program, such as those described by the OSHA 1910.119 standard. MI includes all of the equipment and assets used in production for most facilities, including fixed and rotating equipment. The first step is compiling a list of all of the assets and associated piping or structural diagrams. Then a damage mechanism assessment is performed to figure out what is likely to break and how. This info can then be implemented into an optimized site-wide plan for routine inspection and testing, along with additional plans for inspection when upsets or improper process conditions occur.
Do I Need a Mechanical Integrity Program?
If you’re asking, probably! In the US, OSHA requires that the mechanical integrity of equipment is managed properly to reduced or prevent catastrophic events, including fires, explosions, and release of toxic chemicals. In many other countries, similar laws exist. Perhaps even more importantly, an effective MI program can save you a lot of money with an added bonus of improved safety!
How does Corrosion Affect Mechanical Integrity?
Corrosion is the cornerstone of mechanical integrity – by understanding corrosion, it is possible to predict and prevent it! The proper term for this is “Damage Mechanism Assessment“, and the process is described in API RP 571. While there are courses for learning damage mechanisms assessment, there is no real substitute for experience in this area. Our corrosion experts bring years of experience to bear, and we also work closely with your personnel to understand and utilize your employees’ collective experience as well. When done properly, the process of implementing a process integrity program is a team effort between our experienced corrosion and metallurgical engineers with your experienced employees.