The experts at Asset Optimization Consultants ensure that your company meets the highest standards of development, implementation, and maintenance of Mechanical Integrity, including readiness for the National Emphasis Program (NEP) as well as compliance with OSHA requirements.
Our consultants have designed and implemented hundreds of sustainable Mechanical Integrity Programs, which include an MI Assessment. A Mechanical Integrity Assessment is an interdependent assessment of your:
As a result of a Mechanical Integrity Assessment, you are directed on a path forward that:
Our consultants begin with a visit to your plant to build rapport with your staff as well as become familiar with your existing work processes and procedures, level of personnel qualifications and responsibilities, and technologies for tracking and reporting current work processes. Following our initial visit, we provide assessments in these 11 sessions:
A good Mechanical Integrity System can only be implemented and improved with strong leadership that is supported from the top of the organization. This session addresses the commitment of the site to Mechanical Integrity. Key points include the development and documentation of a mechanical integrity manual and work processes, assignment of responsibilities, employee involvement, compliance audits, and the interaction between other PSM elements.
Procedures and the control of data play important roles in the implementation of an MI system. The MI system should be based upon a well-prepared set of controlled procedures that describe the objectives to be completed, the manner in which they should be completed, and assignment of responsibilities. In addition, the collection of data should be managed in a manner that makes your data useful and available.
The training session addresses the current training that is performed at the site. Training is a required element to assure that all employees who work in a process that contains hazardous chemicals receive training in process overview, safety, and job tasks. The training program must include a training effectiveness evaluation and an opportunity for retraining when necessary.
This session addresses the plan, schedule, and tracking of activities related to Mechanical Integrity. Inspections, tests, and preventative maintenance activities must be performed on a scheduled basis, and the correction of deficiencies must be tracked. A deficiency in these areas is defined as a nonconformance that must be corrected now or later. OSHA 1910.119(j) requires the documentation and tracking of deficiencies until they are corrected.
The Quality Assurance element is necessary to assure that new projects, new construction, maintenance materials, and spare parts are suitable for their intended use. This session evaluates the effectiveness of the QA/QC functions.
This session evaluates the effectiveness of the current system for inspecting and testing pressure-relieving devices, which are part of the pressure-containing envelope. They provide primary protection in the prevention of catastrophic releases of hazardous materials by providing a means for the controlled release of excessive process pressure.
This session ensures compliance with the standards and requirements issued by the American Petroleum Institute. In the past, few industrial sites had an effective program in place for inspecting and testing piping systems. However, the OSHA regulation has defined piping as part of the process system which must be tested and inspected to assure mechanical integrity.
Pressure vessels and storage tanks are specifically addressed in the PSM regulation as part of the pressure-containing envelope. This session ensures compliance with these regulations.
Process controls provide operating information in order to monitor the conditions within the process that contain process changes in equipment and controls. This session addresses emergency shutdown systems, which provide a way to prevent the development of release conditions and to minimize the effects of a release.
This session ensures regulatory compliance of rotating equipment in "covered" processes are included in the Mechanical Integrity system since they provide primary protection in the prevention of the catastrophic release of highly hazardous materials. The OSHA regulation specifically identifies pumps as covered process equipment, but further clarification from OSHA has confirmed that other rotating machinery such as compressors and turbines are expected to be included in the program as well.
OSHA expects electrical systems to be included in a mechanical integrity program because they supply energy to electrical rotating equipment and the critical control systems. With regard to electrical classification, electrical systems are part of the required process safety information. To properly perform this classification, records must be maintained of the inspections and work performed on the electrical systems in the various covered processes. Strengths of the electrical systems test and inspection program will be evaluated as per NFPA 70B and NFPA 110 for inspecting and maintaining emergency power generators.
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.
Asset Integrity Management for all asset families - Rotating, Electrical, Instrumentation, and Fixed Assets
A high level overview intrucing 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?
How do I use GE APM to perform MI/RBI tasks?
Asset Integrity Management - how you perform at the plant level affects those goals set at the board room
A dysfunctionality found in many refineries, chemical plants, and other production facilities, is a lack of common asset management work processes.
A look at how the financial sector's concept of Asset Value Management can be applied to the petrochemical industry.
A look at how RBI adds value whether you are just starting out or transitioning from a traditional methodology.
PHMSA has out for comment, draft document information, that clarifies its jurisdiction in relation to OSHA for Midstream Processing Facilities.
This is a practical approach to incorporating the new PHMSA gas well rules into your integrity program with the rest of your surface and subsurface assets.
Things are always changing. Including your risk profile.
An interesting discussion in which several engineers find common ground.
What are the hidden benefits of implementing Risk Based Inspection?
When working in Brazil please be aware that Brazil has its own Regulatory Standard – NR13 – that covers the minimum requirements for managing the integrity and inspection of steam boilers, pressure vessels, storage tanks and interconnecting pipes.
An example to compliment our earlier proposal for a risk analysis option that allows for individual damage mechanism risk calculation in API 581