Mechanical Integrity (MI) is one of the fourteen elements of OSHA's Process Safety Management (PSM) standard (29 CFR 1910.119) and a parallel requirement under the EPA's Risk Management Program (RMP) rule. The MI element requires employers at covered facilities to ensure that all process equipment is designed, fabricated, installed, operated, and maintained to prevent releases of highly hazardous chemicals. Failure to maintain an effective MI program is among the most frequently cited PSM violations — and more importantly, MI failures are a direct cause of process safety incidents that injure and kill workers.
At Precision MCS (PMCS), we provide comprehensive mechanical integrity inspection services that help process facilities establish, execute, and document their MI programs to meet regulatory requirements, protect employees, and maintain reliable operations. Our inspectors bring field-proven expertise in PSM-covered facilities including refineries, chemical plants, ammonia refrigeration operations, and natural gas processing facilities.
Under OSHA PSM, the Mechanical Integrity element applies to a defined set of equipment categories: pressure vessels and storage tanks, piping systems including valves, pressure relief devices, emergency shutdown systems, controls including monitoring devices, sensors, alarms, and interlocks, and pumps. Maintaining the mechanical integrity of these systems requires a structured program that goes well beyond periodic visual inspection — it requires documented procedures, qualified inspection personnel, defined inspection intervals, systematic tracking of deficiencies, and quality assurance oversight of all maintenance activities involving process equipment.
PMCS supports all elements of a complete MI program. Equipment identification and criticality classification establishes a complete inventory of covered equipment and assigns criticality ratings based on failure consequences, hazard levels, and regulatory applicability — the foundation of a defensible inspection program. Written inspection and testing procedures developed or reviewed by PMCS inspectors provide clear, location-specific instructions for how each equipment type is to be inspected, what acceptance criteria apply, and how results are to be documented. Qualified inspection personnel supply certified inspectors with the appropriate credentials and field experience for each equipment category inspected. Inspection intervals are established based on applicable codes, equipment history, corrosion rates, and risk ranking, ensuring that inspection resources are allocated efficiently and that high-risk equipment receives the scrutiny it warrants. Equipment deficiency tracking ensures that every finding from an inspection is documented, assigned a corrective action, tracked to resolution, and reviewed for safety significance before equipment is returned to service. Quality assurance oversight of maintenance activities verifies that repairs, alterations, and replacements involving process equipment are performed to applicable codes and standards using documented procedures and qualified personnel.
PMCS mechanical integrity inspections apply a wide range of inspection techniques calibrated to the specific damage mechanisms and failure modes relevant to each equipment type. For pressure vessels, we apply API 510 inspection methodology including internal and external visual assessment, ultrasonic thickness measurement, and NDE techniques appropriate for the damage mechanisms present. For piping systems, we apply API 570 inspection methodology covering all piping circuits in the facility, identifying injection points, dead legs, corrosion under insulation (CUI), and other high-corrosion-rate locations. For pressure relief devices, we verify correct installation, assess physical condition, and confirm that test and maintenance records are current and compliant with API 576 requirements. For rotating equipment, we assess casing, seal, bearing, and coupling conditions and review vibration monitoring records. For instrumentation and controls, we verify that safety instrumented systems (SIS) are tested and documented per IEC 61511 requirements.
PMCS maintains meticulous records for every MI inspection activity performed. Our documentation package for each inspection includes equipment identification, inspection scope and methods, quantitative measurements and findings, comparison to previous inspection data, code compliance assessment, deficiency list with corrective action requirements and priority classifications, inspector credentials and certifications, and a fitness-for-continued-service determination. These records are maintained in a format consistent with PSM audit requirements and are designed to withstand regulatory scrutiny. PMCS inspectors are also available to support PSM compliance audits and incident investigations where MI program documentation is reviewed.
PMCS provides MI inspection services to any facility subject to OSHA PSM or EPA RMP requirements, as well as facilities that have voluntarily adopted MI programs as a best practice. This includes petroleum refineries, chemical and petrochemical plants, ammonia refrigeration operations, LPG storage and distribution facilities, natural gas processing plants, pulp and paper mills, pharmaceutical manufacturing operations, and other process industries. Regardless of the size or complexity of your facility, PMCS has the experience and inspection capabilities to support your MI program effectively.
API 570-compliant piping inspection services covering thickness measurement, corrosion assessment, CUI evaluation, and fitness-for-service determinations for process piping systems of all types.
Certified inspections of all flame arrestor types — deflagration, detonation, in-line, and end-of-line — documented to API 2000, NFPA 67, and EN ISO 16852 standards.
