Mechanical Integrity 101 for Process Safety Professionals

This paper prepares you to evaluate your existing practices versus recognized codes and standards and then to efficiently improve or develop and implement your mechanical integrity (MI) program. Topics also include linkages of MI to Process safety and reliability, What a “Good” MI Program looks like, and How to measure success

Typical Audience

• Designated employee responsible for designing, developing, and implementing a PSM based MI program
• Managers – Plant Manager, Maintenance, and Production
• PSM Manager or Coordinators

What You Will Learn

• Up-to-date MI strategies and techniques for effectively building and implementing a comprehensive MI program that addresses process safety management requirements and/or reliability and other concerns as defined through company, industry, and regulatory requirements
• How to expand this program to encompass reliability and quality goals
• How to define and assign roles and responsibilities
• How to integrate your new or revised MI program with existing MI activities
• How inspection plays a key role in a successful program
• Quality assurance methods for identifying and resolving equipment deficiencies
• How to develop maintenance procedures and training programs for maintenance personnel
• How to develop a maintenance procedures list for your plant site

Detailed topics covered in paper

• Learning objectives and goals for mechanical integrity (MI)
• Motivations for mechanical integrity
• Regulations, standards, and interpretations
• Relationship to Reliability programs
• Designing a mechanical integrity program
  • Minimal MI program only for compliance?
  • Fully integrated reliability program?
  • Something in-between?
  • Developing a mechanical integrity program
  • Equipment identification and related issues
  • List of critical equipment
  • Types of MI activities (reactive, proactive, preventive, predictive)
  • Choosing the right task type and choosing the specific task
  • Determining the right frequency for the task (condition or time dependent)
  • Personnel focus
    • Procedures
    • Training

• Management systems required and related issues
  • Quality assurance
  • Equipment deficiency resolution
  • Root cause analysis
  • Management of change
  • Implementing/Maintaining a mechanical integrity program
  • Review of detailed checklist for implementing an MI/reliability system
  • Documenting and managing data/results, computer systems and other
    equipment files
  • Roles and Responsibilities for MI
  • Key performance indicators for MI and continual improvement of a mechanical integrity program

About the author

Robert C. Smith, Senior Consultant at ABB, Inc, has, over the past 20 years, helped develop and launch key process management initiatives for Oil & Gas, Chemical, Manufacturing and Pharmaceutical clients throughout the world.

As an integral member of ABB’s Consulting arm, Rob works with clients all over North America. Rob’s performance-based recommendations consistently lead corporations to a higher degree of safety, profitability and sustainability.

His company, Risk Control Services helped clients achieve true economic value through his top-down approach to business performance and risk management. Building safety cultures is Rob’s signature approach to sustainability.