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Mechanical
Integrity
OSHA issues the most PSM citations
for the Mechanical Integrity (MI) element of PSM. This is undoubtedly
due to its complexity. Many companies find it the most difficult of the
fourteen PSM elements to address.
The objective of Mechanical Integrity
is to ensure equipment does not fail in a way that causes or affects a
release of covered chemicals. Equipment means hardware that helps
contain the chemicals in the process. MI covers the proper design,
fabrication, construction/installation and operation of equipment
throughout the entire process life cycle.
MI is not just maintenance, although
maintenance is a major part of an MI program. Other activities are
involved such as training and quality assurance.
MI programs typically cover these
areas:
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Management system
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Identification and
categorization of covered equipment
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Applicable codes and
standards
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Maintenance tasks
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MI procedures
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MI training
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Inspection and testing
(Preventive/Predictive Maintenance (PM))
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Correction of
deficiencies in equipment
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Quality Assurance (QA)
program
Services Offered
Primatech helps companies establish
new MI programs and refine existing programs to make them more effective
and help ensure regulatory requirements are met.
Our work covers:
Management System – Any activity
important to an organization must be managed. This requires policies,
procedures, work instructions and documentation. Primatech works with
clients to ensure responsibilities are assigned, authority is given,
supervision is provided, resources are made available, and people are
held accountable for MI activities.
Covered Equipment – OSHA defines
specific types of equipment that must be included in a MI program.
However, this is not intended to be a complete list. Also, while the
name of the element implies only mechanical equipment is covered, other
equipment which might contribute to a catastrophic release must also be
included, for example, electrical equipment. Primatech helps clients
determine what equipment should be included in their MI program.
Codes and Standards – There are
many industry codes and standards that apply to MI, particularly for
design and engineering and preventive maintenance. These must be
documented. Primatech assists clients with this process.
Maintenance Tasks – Facilities
typically employ a combination of breakdown and preventive maintenance.
Primatech helps clients to develop appropriate programs that balance
these approaches to maintenance.
MI Procedures – Written procedures
must be developed and implemented for key activities including
maintenance. Primatech works with clients to develop procedures that
emphasize usability.
MI Training – MI personnel must be
appropriately trained for the tasks they will perform. Primatech helps
design suitable training programs.
Inspection and Testing – OSHA
emphasizes the use of preventive maintenance. Primatech helps companies
develop procedures and schedules for inspection and testing of critical
process equipment.
Controlling and Managing Deficiencies
– Equipment deficiencies found during tests and inspections must be
addressed before further use, or in a safe and timely manner when
necessary means are taken to assure safe operation. Primatech helps
companies to determine safe operating limits and to develop procedures
for addressing deficiencies.
Quality Assurance (QA) – Primatech
helps companies develop procedures for quality assurance for equipment
procurement, fabrication, installation, repair, and spare parts,
maintenance materials and equipment.
Primatech provides
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A thorough understanding
of applicable regulatory requirements;
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A proven and effective
approach to MI;
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The ability to integrate
the MI program with existing company maintenance procedures, safe
work practices, computerized maintenance management systems (CMMS),
etc.;
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Experience in developing
MI programs for a variety of companies in the process industries
Primatech offers the training courses
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