Mechanical Integrity Programs

MISTRAS provides customized solutions for mechanical integrity (MI) programs of any maturity level, helping operators enhance asset reliability, ensure regulatory compliance, and optimize operational efficiency.

Mechanical Integrity (MI) programs are essential for ensuring the safe, reliable, and efficient operation of industrial assets. These programs are designed to prevent equipment failures, enhance compliance with regulatory standards such as OSHA Process Safety Management (PSM) and EPA Risk Management Program (RMP), and extend the lifecycle of critical infrastructure. A robust MI program helps operators in industries like oil and gas, petrochemicals, chemicals, and power generation identify and mitigate potential risks before they escalate, supporting continuous operational productivity and safety.

At every maturity level, MISTRAS can help advance your MI Program. Our solutions are designed to enhance asset reliability, ensure compliance with regulatory standards, and optimize operational efficiency through tailored approaches and advanced methodologies.

Asset Integrity Program Development

MISTRAS offers expertise in developing robust asset integrity management (AIM) programs tailored to your operational needs. These programs focus on ensuring the safety, reliability, and performance of critical equipment, including:

• Fixed & Rotating Equipment: Solutions for managing pressure vessels, pumps, compressors, and other static and dynamic assets.
• Instrumentation, Controls, & Electrical: Integration of control systems to maintain operational precision and compliance.
• Policies & Procedures: Development of governance documents aligned with API, ASME, and OSHA standards to streamline operations and enhance safety.

Equipment Data Gathering

To establish a solid foundation for your MI program, we provide comprehensive equipment data collection services, ensuring accurate and actionable insights:

• Asset Register: Creation and management of detailed equipment inventories to track critical assets.
• Process Safety Information: Compilation of critical data for pressure relief systems, piping, and process units to support safety and compliance.
• Digitization of Legacy Data: Converting historical inspection and maintenance records into accessible, digital formats for improved traceability and data analytics.
• Systemization/Circuitization: Determine and develop corrosion loops and circuits on facility Process Flow Diagram PFD and Piping & Instrument Diagram (P&ID) drawings to implement findings from damage mechanism reviews 

Inspection, Testing, & Preventive Maintenance (ITPM) Programs

Our customized ITPM solutions are designed to mitigate risk, comply with industry standards like API 510, 570, and 653, and extend the lifecycle of critical assets:

• Customized ITPM Program: Tailored inspection and testing plans to meet your facility’s unique needs and regulatory requirements.
• Inspection Plan Development: Strategic planning to optimize resource allocation and maintain compliance with API and ASME codes.

Reliability-Centered Maintenance (RCM)

Reliability Centered Maintenance (RCM) is a systematic approach used to ensure that assets continue to perform their intended functions within their operating context. By identifying potential failure modes and understanding their consequences, RCM helps prioritize maintenance tasks that maximize reliability, minimize downtime, and optimize maintenance costs.

MISTRAS leverages industry-proven RCM techniques to enhance asset reliability and reduce downtime:

• Failure Mode and Effects Analysis (FMEA): Identifying potential failure points in refinery units, chemical plants, and manufacturing facilities to prioritize mitigation efforts.
• Asset Criticality Assessment: Evaluating the importance of assets based on operational risk, production impact, and safety considerations.

RAGAGEP Expertise

MISTRAS helps ensure that your MI program aligns with Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) to meet regulatory requirements and optimize safety:

• OSHA PSM 1910.119(j) & EPA RMP 40 CFR 68.73: Ensuring compliance with federal process safety standards.
• Member of API Subcommittee: Direct involvement in shaping industry standards and ensuring best practices.
• ASME VIII Div 1 & 2, B31.3, and more: Comprehensive expertise in critical engineering codes for pressure vessels, piping, and structural components.

Inspection Data Management Software (IDMS) Implementation

• MISTRAS offers comprehensive Plant Condition Management Software (PCMS) by MISTRAS implementation services, including data management, training, consultation, and technical support, to enhance system performance and ensure efficient operations.
  Data support services such as data evaluation, entry, auditing, and KPI reporting.
• Technical support for RBI, DMRs, systemization, and corrosion control.
• Turnaround data implementation and document management services.
• Customized training and consulting for tailored program execution and support.

Complementary Asset Protection Services

In addition to MI Program Development, MISTRAS offers a range of complementary solutions to provide end-to-end asset integrity management, including:

• Advanced and Traditional Non-Destructive Testing (NDT): Industry-leading toolbox of available NDT/NDE techniques to execute mechanical integrity program inspection requirements.
• Risk-Based Inspection (RBI): Advanced methodologies to prioritize inspections based on risk profiles and damage mechanisms.
• Condition-Based Maintenance (CBM): Real-time monitoring solutions to optimize maintenance schedules and reduce downtime.