What Does Mechanical Integrity (MI) Program Assessment mean?

MI Program Assessment is a type of systematic evaluation process that focuses on the inspection, testing, and maintenance planning aspects of your equipment and facilities. MI involves an extensive examination of your mechanical systems, structures, and assets to identify any deficiencies or potential risks that may compromise their reliability.

How Does MI Program Assessment work?

We have an experienced team that will collaborate closely with your organization to conduct a comprehensive assessment of your MI program. This assessment process typically involves the following steps:

What are the Benefits of Mechanical Integrity Program Assessment?

By opting for our MI Program Assessment service, you can expect to gain the following benefits:

1. Improved Safety & Compliance: You can create a safer working environment for your personnel and ensure compliance with industry regulations and standards, by addressing integrity concerns. This can eventually help you avoid costly fines, reputational damage and legal issues.
2. Extended Asset Life Cycle: You can extend the life cycle of your equipment by proactively addressing integrity issues and implementing proper inspection practices. This can result in significant cost savings by avoiding premature equipment replacement or costly repairs.
3. Optimized Inspection Planning: Our assessment process helps you optimize your maintenance planning by identifying critical assets, determining appropriate inspection and testing frequencies, and implementing effective inspection strategies. This can lead to improved operational efficiency and cost savings.
4. Enhanced Equipment Reliability: We help you identify and rectify potential integrity issues, reducing the risk of unplanned equipment failures and maximizing the reliability of your assets through our comprehensive assessment and remediation strategies.

CORROSION CONTROL DOCUMENTS (CCDs) & INTEGRITY OPERATING WINDOWS (IOWs)

What are Corrosion Control Documents (CCDs)? These are detailed guidelines and procedures aimed at managing and mitigating corrosion, which is an essential component of asset integrity management. The CCD outlines preventive measures, inspection techniques, maintenance procedures, material selection, and corrosion mitigation strategies.

What are Integrity Operating Windows (IOWs)? These are predetermined operating limits and conditions within which systems, equipment and processes can operate to maintain the desired level of integrity. These limits are based on engineering analysis, industry standards, such as API 584, and operational experience to ensure safe and reliable operations. After defining these operating parameters, organizations can monitor and control these parameters within the defined IOW, helping them proactively manage risks, prevent equipment failures, and maintain the integrity and age of critical assets.

How are CCDs & IOWs developed?

Our dynamic approach to CCD & IOW development starts with a comprehensive assessment of your assets, considering their specific characteristics, operating conditions, and historical corrosion data. Our team of experts analyzes the collected information to develop customized CCDs and define appropriate IOWs tailored to your specific needs.

The CCD includes a corrosion management plan that outlines proactive measures, such as coatings, cathodic protection, and chemical treatments, to prevent or minimize corrosion. It also incorporates regular inspection and monitoring programs to detect any signs of corrosion and degradation, enabling timely identification and monitoring.

IOWs are established based on a through engineering analysis of equipment limits, environmental conditions, process variables, and safety requirements. By defining the acceptable ranges for key parameters, such as pressure, temperature, flow rates, and chemical concentrations, IOWs provide operators with clear guidelines to ensure safe and efficient operation while mitigating integrity threats.

What are the Benefits of CCDs & IOWs?

Operational Reliability: Implementing best practices outlined in CCDs and adhering to IOWs leads to improved operational reliability. By effectively controlling corrosion and operating within specified conditions, you can extend the life of your assets, optimize inspection efforts, and ensure consistent performance, ultimately leading to increased operational efficiency.

Enhanced Process Safety and Integrity: You can significantly enhance the safety and integrity of your assets by implementing CCDs and adhering to IOWs. Proactively managing corrosion and adhering to operating windows minimizes the likelihood of equipment failures, leaks, and other incidents that could jeopardize personnel safety and harm the environment.

Risk Management: CCDs and IOWs are powerful risk management tools. They enable you to identify and address potential integrity issues before they escalate, reducing the likelihood of costly repairs, unplanned downtime, production losses. This proactive approach helps you maintain a reliable and compliant operation.

Risk-Based Inspection (RBI)

What Does Risk-Based Inspection mean? Risk-Based Inspection is a methodology that focuses on prioritizing inspection efforts based on the likelihood and consequences of asset failure. It utilizes a systematic and qualitative, semi-qualitative or quantitative approach to assess risks associated with assets, enabling informed decisions regarding inspection planning and resource allocation.

How does Risk-Based Inspection work? Our Risk-Based Inspection process involves a comprehensive analysis of asset condition, historical data, and operational parameters to determine the likelihood of failure and potential consequences. By considering factors such as asset criticality, damage or degradation mechanisms, inspection effectiveness, and regulatory requirements, we develop a risk matrix that ranks assets based on their risk levels. This risk ranking guides the development of an optimized inspection plan, focusing resources on assets with the highest risks.

Our experienced professionals combine expertise in asset integrity, risk analysis, material science, and inspection techniques to tailor the Risk-Based Inspection process to your specific industry and asset types. We leverage advanced software tools and industry best practices, such as API 580 and API RP 581, to perform the risk assessment, allowing for accurate identification and prioritization of potential risks.

What are the Benefits of Risk-Based Inspection?

1. Improved Asset Performance and Lifespan: Through proactive risk assessment and targeted inspections, potential asset degradation and failure can be detected early, enabling timely interventions and maintenance activities. This proactive approach helps extend the life of your assets, maximize their performance, and avoid costly asset replacements.
2. Compliance with Regulatory Standards: Our Risk-Based Inspection service ensures that your inspection and maintenance practices align with regulatory requirements and industry standards. By implementing a systematic and documented approach to risk assessment and inspection planning, you can demonstrate compliance with regulatory authorities, minimizing the risk of penalties and legal complications.
3. Enhanced Safety and Reliability: By prioritizing inspection efforts on assets with the highest risks, our Risk-Based Inspection service helps identify potential failure modes before they occur, reducing the likelihood of accidents, unplanned downtime, and costly repairs. This approach improves the overall safety and reliability of your assets, protecting both personnel and the environment.
4. Cost Optimization: RBI allows for efficient allocation of inspection resources, eliminating unnecessary inspections on low-risk assets. By focusing on critical areas, you can significantly reduce inspection costs while maintaining the integrity of high-risk assets. This optimization leads to substantial cost savings in inspection planning, maintenance, and repair activities.