Mechanical Integrity (MI): What Makes a Good Program?

Ensuring Mechanical Integrity (MI) is critical for safe, reliable operations. That’s why heavy process facilities should make having an effective MI program a top priority.

But what makes a “good” MI program?

According to the Occupational Safety and Health Administration’s (OSHA) Process Safety Management Standard (PSM), a mechanical integrity program should “[prevent or minimize] the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals.”

While MI programs should, at a minimum, make sure activities are in place to ensure equipment is fit for service and that loss of containment events are avoided, a highly effective MI program will manage the operation and maintenance of critical process equipment in a way that safely manages risk, maximizes operational availability, and optimizes maintenance and inspection spend.

Oftentimes, many initiatives are put into place to efficiently achieve Mechanical Integrity. However, these initiatives are frequently ineffective because they are not properly implemented, worked on in siloes, and/or overlap one another, among other issues. Organizations suffering from these issues due to lack of a planned approach often suffer from unnecessary costs, uncontrolled documentation, poor communication, uninformed decisions, and wasted time and efforts.

Making Your MI Program More Efficient

As a mechanical integrity leader, there are two things you must know:

  1. Are the right things being prioritized?
  2. How are these priorities going to pay off in the short and long term?

To answer these questions, we recommend evaluating your site practices and performance—the result of which will highlight the most valuable opportunities for improving your mechanical integrity program.

PinnacleART's Comprehensive Reliability Solution

For organizations looking to achieve an MI program of best in class caliber, PinnacleART provides the expertise, state of the art technology, and proprietary methodologies to deliver a world class program within a specified time frame. Whether your facility is large or small, a comprehensive approach is essential to running a safe and effective program, and PinnacleART is able to is able to assess your facility and create a completely customized and integrated MI program.

Our approach is composed of three steps.

1. IDENTIFY PERFORMANCE OPPORTUNITIES & BUILD IMPROVEMENT PLAN
2. EXECUTE IMPROVEMENT PLAN
3. SUSTAIN RELIABILITY

Performance opportunities are identified across plants, units, and equipment types in both lost production and maintenance spend. We then build an improvement plan by plant and unit, prioritizing quick wins that will close spending and lost production gaps.

PinnacleART’s project teams execute the improvement plan, utilizing the horsepower and expertise of roughly 1,000 people and the efficiencies of an array of in-house implementation tools. The result is an efficiently implemented improvement plan and minimal use of site resources.

Programmatic improvements are sustained through actionable reliability insights for both equipment and program. The goal is to keep the facility performing at a best-in-class level.

Want to Learn More?

Visit our Solutions page to discover how we support MI programs for your industry.

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