MI Compliance Checklist

Mechanical Integrity (MI) Compliance Checklist

Version 1.0

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.

MI Compliance Checklist

Evaluate Your Mechanical Integrity Program

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.

How to Use This Tool

  • Review and Assess: Go through the list of essential MI program elements. These questions are based on industry best practices and our proven audit methodology.
  • Check All That Apply: Select each element that is currently a part of your program. Be thorough and honest in your assessment.
  • Add Comments: Use the provided comment field to offer justifications, explain why an element may not be present, or note any mitigating controls. This helps in building a more complete picture of your program's status.
  • Receive Your Report: Upon submission, you will receive a detailed email report. This personalized analysis will summarize your results and provide targeted recommendations to address any gaps and improve your program's compliance and effectiveness.

This tool is a first step toward identifying areas for strategic improvement, helping you proactively enhance safety and reduce risk within your operations.

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1: A program has been developed that offers guidance, procedures, and instructions for implementation of the Mechanical Integrity System.
Comment if unchecked.
2: A formal audit of compliance of the MI system with regulations is conducted periodically.
Comment if unchecked.
3: Written procedures exist to maintain the ongoing integrity of covered process equipment. The following equipment types are included in these procedures
  • Pressure Vessels
  • Storage Tanks
  • Piping Systems and Circuits
  • Relief Devices
Comment if unchecked.
4: Up-to-date P&IDs are available for each process unit.
Comment if unchecked.
5: A system is in place that advises supervisors when inspection or corrective actions are scheduled.
Comment if unchecked.
6: Deficiencies are documented and tracked until corrected.
Comment if unchecked.
7: An established process is in place which defines the requirements for extending inspections and deficiency corrections beyond their established due dates.
Comment if unchecked.
8: Each employee involved in maintaining the ongoing integrity of covered equipment has been trained in the procedures applicable to the employee’s job tasks.
Comment if unchecked.
9: A system is in place to verify that new or replacement equipment as it is fabricated is suitable for the intended process application.
Comment if unchecked.
10: The recognized and generally accepted good engineering practices that are applicable for the pressure vessels and storage tanks have been identified.
Comment if unchecked.
11: Each inspection and test performed on covered pressure vessels, storage tanks, piping circuits, and relief/vent devices are documented with the following information:
  • Identification of the equipment being inspected
  • Date of the task
  • Name of the person who performed the task
  • Description of the task and extent of the inspection/test
  • Results of the task
Comment if unchecked.
12: Pressure vessels, storage tanks, piping circuits, and relief/vent devices are inspected by Assigned Persons who are qualified by documented training and certification.
Comment if unchecked.
13: Inspections and/or measurements which do not meet acceptable limits are deficiencies and are corrected before further operation, or in a safe and timely manner when interim means are taken to assure safe operation.
Comment if unchecked.
14: The Management of Change procedure applies to changes in the design data and the process operating limits for each equipment/component. PSM requires those maintaining the MI system be notified of of those changes so that damage mechanisms can be reevaluated and inspection plans can be reviewed.
Comment if unchecked.

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Asset Optimization is the authority on asset integrity solutions that align your people, process, and technology with unmatched returns across your enterprise.

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