Mechanical Integrity (MI) is based on managing equipment and assets within your business, from installation through their entire lifecycle and eventual obsolescence. MI is a vital, if not the biggest, part of incident and injury prevention, and critical to Process Safety Management. The safety and well-being of employees depend on the quality and reliability of the equipment they work with, so it is vital that everything, even the smallest maintenance task, gets tracked.

MI goes beyond routine maintenance; it’s a comprehensive approach to ensuring the reliability, safety, and longevity of critical process equipment throughout its lifecycle. It keeps track of whether your equipment:

• Is installed correctly
• Operates as it should
• Is maintained well

An MI program helps manage your inspections – contributing to audit readiness and compliance with industry regulations.

Key elements of a robust MI program

MI doesn’t only address safety requirements but contributes to strategies aimed at reducing risk as well as optimizing the life cycle of your assets and equipment. The combination of reducing both risks and costs is the key to operational excellence, and MI takes you in the right direction.

The key elements of a successful mechanical integrity process include:

#1. Selection of the right equipment

Choosing equipment tailored to your specific operational needs sets the foundation for a robust MI program. You should consider factors such as reliability, durability, and compatibility with existing infrastructure.

#2. Implementation and inspection

Thorough implementation processes and regular inspections ensure that equipment is installed correctly and operates as intended. Regular inspections help identify issues early, allowing for proactive maintenance that minimizes the risk of equipment failure and unexpected downtime.

#3. Testing

Routine testing helps you verify the integrity and functionality of equipment. These tests serve as a proactive measure to detect any anomalies before they escalate into safety hazards or disruptions to your operations.

#4. Proactive maintenance strategies

Proactive maintenance strategies, such as predictive maintenance and condition monitoring, can significantly improve equipment reliability and performance. By addressing issues before they escalate, you can increase the lifecycle of your equipment.

#5. Selection of the right people for the right tasks

Assigning competent personnel to oversee MI tasks is essential. Skilled individuals with the necessary expertise and training ensure that inspections and maintenance activities are completed safely, effectively, and efficiently.

While MI presents numerous benefits, with such a list of tasks and personnel involved, it also brings some challenges to the table.

The challenges of MI

MI is a critical part of incident prevention, but it’s challenging considering its scope. The first challenge is to define everything that MI encompasses for your company. This involves identifying all relevant equipment, processes, and associated maintenance tasks.

The next challenge is bringing together the different systems you have in place for equipment management, communication, inspections, employee management, etc. They cannot be separated, or things will head south.

A simple example: having to dig through paper or digital spreadsheets for inspection results, only to then have to find that e-mail thread in which the inspection was discussed to bring the information together. That’s a headache.

Seamless integration is essential to avoid siloed data and inefficiencies that can compromise the effectiveness of MI efforts. Software is the surest way to tie everything together!

Overcoming the challenges with software

Implementing specialized EHSQ software is the key to integrating and managing all aspects of MI within a centralized platform. With TenForce EHSQ software, you’re not just getting a tool; you’re gaining access to a customized environment designed to streamline your workflow.

Everything you need is at your fingertips. You can find relevant information, notify the right people, and track your data — all without having to navigate away or dig through multiple sources. In just a matter of minutes, you can find details about equipment installation, maintenance history, and inspection results.

By integrating Mechanical Integrity with TenForce’s suite of PSM modules, you can gain a complete overview of your entire operation, at the tap of a finger. Let us show you how: find out more and book a demo today!