Mechanical Integrity Programs

A Mechanical Integrity Program is required to comply with OSHA 1910 “Process Safety Management”.  The purpose of the program is to ensure that equipment used to process, store, or handle highly hazardous chemicals is designed, constructed, installed, and maintained to minimize the risk of releases.  Equipment included in a mechanical integrity program includes pressure vessels, storage tanks, process piping, relief and vent systems, fire protection system components, emergency shutdown systems and alarms and interlocks and pumps.

Why do you need a Mechanical Integrity Program?

• Good mechanical integrity makes a plant safer.
• Environmental Protection. Good mechanical integrity helps keep hazardous materials contained.
• Good mechanical integrity helps reduce equipment breakdowns and unplanned outages, reduces repair / replacement costs, improves plant efficiency and product quality.
• Regulatory Compliance. Mechanical integrity programs are mandatory for many industrial processes.
• Litigation Risk Management. Good mechanical integrity programs and compliance reduces the risk of litigation.

The Mechanical Integrity Program must include:

• A formal, documented “management system”.
• The identification and categorization of covered equipment.
• Reference to applicable codes and standards.
• Description of maintenance tasks.
• Formal, documented Mechanical Integrity procedures.
• Formal, documented Mechanical Integrity training.
• Inspection, testing, and predictive/preventive maintenance procedures.
• The correction of deficiencies in equipment.
• A Quality Assurance (QA) program.

OSHA issues more citations for the Mechanical Integrity element of Process Safety Management than all of the other elements combined.  Many companies find Mechanical Integrity to be the most difficult element of Process Safety Management to manage.

We have over 35 years of experience auditing, assessing, developing and improving Mechanical Integrity programs.  If you have processes at your facility that are covered by OSHA 1910 and you struggle with the complexity of the Mechanical Integrity requirements, please contact us.  We can help.