Assess your plant's Mechanical Integrity (MI) program for compliance with key safety regulations like OSHA 1910.119. This interactive checklist provides a clear snapshot of your program's strengths and identifies areas for improvement, helping you maintain a safe and compliant facility.

Maintaining a robust Mechanical Integrity (MI) program is critical for ensuring the safety and operational reliability of your plant. A well-managed program helps prevent catastrophic failures, protects personnel, and ensures compliance with stringent regulations, including OSHA's Process Safety Management (PSM) standard (1910.119).
This comprehensive checklist, developed from AOC's extensive experience with formal MI audits, allows you to objectively evaluate your current program. It is designed for plant managers, engineers, and maintenance personnel who are responsible for maintaining a compliant and effective MI system.
This tool is a first step toward identifying areas for strategic improvement, helping you proactively enhance safety and reduce risk within your operations.
Key parameters and mitigating actions for variables that may dramatically affect the intended design life of your asset
A maintenance system designed in which elements work together as a quality system for maximum returns
AOC delivers the policies, procedures, work processes, knowledge and actions such as preventive maintenance, predictive maintenance, and condition monitoring tasks.
Create mechanical integrity (MI) program value rather than it being seen as a necessary cost to minimize.
A high level overview introducing Mechanical Integrity and Risk Based Inspection
What are your goals for RBI? How will you measure your success? How will you sustain that success?
How important are they?
What impact does Risk Based Inspection (RBI) have on my organization?
Is your Risk Based Inspection (RBI) program aligned with the API 580 Recommended Practice? Are you ready for certification?
A formal acceptable risk policy standardizes risk tolerance, assigns decision authority by risk level, and requires escalating approvals for higher risk, improving consistency, transparency, and resource prioritization while preventing unmanaged risk exposure.
Unified framework integrating MI, RCM, PHA, and SIL/SIS into one risk-based system using a common matrix, shared failure modes, and closed-loop feedback to align actions, prioritize resources, and ensure consistent, real-world risk reduction.
MOC fails not from lack of knowledge, but from conflict with operational pressures. Speed is rewarded over rigor, definitions are unclear, ownership is weak, and risk reviews become procedural, allowing changes, cumulative risk, and hazards to go unmanaged.
Practical guide for implementing a Mechanical Integrity and RBI program for U.S. oil and gas wellfield, gathering, and midstream facilities. Aligns lifecycle asset management, inspection, and risk control with API standards, PHMSA pipeline rules, and OSHA PSM requirements.
Organizations that follow the spirit of risk-based inspection rather than its minimum requirements use a definable, structured, auditable process to confirm that an alternate inspection technique provides equal or better risk reduction than a baseline method.
The U.S. refining industry recorded nine significant fires and explosions in 2025. While the count is low, incidents at Chevron and HF Sinclair highlight the critical need for robust mechanical integrity and process safety programs.
Why companies overlook Mechanical Integrity: It's expensive, exposes risk, requires specialized knowledge, and is difficult to audit. Learn the 10 structural, cultural, and economic reasons MI is the weakest PSM element.
Discover why equipment failure is the root cause of most catastrophic incidents. Mechanical Integrity (MI) is the non-negotiable foundation that prevents loss of containment and protects your entire PSM system. Learn the 8 reasons MI is essential.
Refinery incidents, especially fires & explosions, appear to be increasing since 2018, though industry-reported safety metrics show a drop. We look at the data, the debate, and why the numbers conflict.
PHMSA vs. OSHA: Understanding the Overlap Hydrocarbon facilities like pipelines, refineries, and terminals often fall under both PHMSA (DOT) and OSHA (DOL). Learn where each agency's jurisdiction begins and ends, and how to coordinate your integrity programs for compliance.
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