Mechanical Integrity

Mechanical integrity refers to the management of crucial process equipment to ensure that it gets designed and installed correctly plus maintained properly.

Focus

A mechanical integrity program should include procedures for inspection and testing of equipment by using recognized engineering practices (RAGAGEP) and the suitability of newly-fabricated equipment for usage.

Why PMET

PMET provides comprehensive mechanical integrity (MI) and asset integrity management (AIM) elements and plant processes.

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Mechanical integrity refers to the management of crucial process equipment to ensure that it gets designed and installed correctly plus maintained properly. A mechanical integrity program should include procedures for inspection and testing of equipment by using recognized engineering practices (RAGAGEP) and the suitability of newly-fabricated equipment for usage. It is also important that employees responsible for maintaining the equipment’s continual integrity are sufficiently trained.

To effectively create and carry out, Pittsburgh Mineral & Environmental Technology (PMET) provides comprehensive mechanical integrity (MI) and asset integrity management (AIM) elements and plant processes. Our team of specialists has experience with MI and asset integrity services that can help you develop a program that meets regulatory standards.

Asset Integrity Services

PMET assists infrastructure, facilities, and equipment assets with asset integrity management through the conception, design, construction, commissioning, operations, and decommissioning phases.

Asset management aims to use corporate assets to their most significant potential while minimizing risk, keeping personnel safe, protecting the community, and conserving resources. Because these areas influence infrastructure and equipment integrity, a genuine asset integrity management program incorporates design, maintenance, inspection, process, operations, and management ideas.

Asset Integrity

Management Services

 

We specialize in asset integrity management services for our clients, which maximize equipment reliability and availability.  This also helps minimize maintenance expenses and increases staff and equipment productivity from deployment to end of life. 

Failure analysis

  • Finite element analysis (FEA)
  • Corrosion
  • PipeAware – Tracking Pipe Inspection Data
  • Fitness for service (FFS)
  • Fracture toughness testing
  • Technical Inspections
  • Predictive Analytics for the Energy Industry
  • Dimensional Control
  • Fatigue testing
  • Metallurgical testing
  • Non-destructive testing (NDT) and inspection
  • Residual lifetime assessments (RLA)

What Does a Mechanical Inspector Do?

Mechanical inspectors are experts who check for electrical, structural, and other mechanical systems. They must ensure that machinery like boilers, HVAC systems, and elevators are running correctly and that the work is up to code. These inspectors must be able to interpret engineering drawings and specification standards while checking material quality and deciding if items are acceptable.

Mechanical Integrity

Program Services

We provide unique and all-encompassing solutions for Mechanical Integrity Programs. Oil, gas, and chemical facilities rely on Mechanical Integrity Programs (MIP) to maintain safety and dependability. OSHA, PHMSA, and SEMS require industry compliance with regulatory standards.

We offer a comprehensive scope of services and solutions, such as those mentioned below, tailored to each facility’s specific needs.

  • Deficiencies in equipment must be resolved to an acceptable level.
  • Written procedures should be in place for inspection and maintenance staff.
  • Appropriate identification and asset selection (pressure vessels; storage tanks; piping; relief devices)
  • Requirements for training, certification and accreditation of employees are always up to date.
  • Scheduled activities for inspection, testing, and preventative maintenance.
  • Spare parts and new equipment must be monitored for quality assurance.
  • Manage your Mechanical Integrity Program using excellent performance metrics.

Mechanical Integrity Procedure and Process Safety

A mechanical integrity procedure is a set of steps that ensure the equipment in a process plant can operate safely and reliably.

The procedure is designed to prevent failures that lead to leaks, spills, or explosions. Critical components of a mechanical integrity procedure include:

  • Identification of critical equipment and piping
  • Inspection and testing schedules for critical equipment and piping
  • Procedures for repairing and replacing defective equipment and piping
  • Training for employees who operate and maintain critical equipment and piping

When developing a mechanical integrity procedure, it is essential to consider the entire life cycle of the equipment and piping. The procedure should be designed to prevent problems from occurring and identify and correct problems that arise. By following a mechanical integrity procedure, companies can ensure the safety of their employees and the public and avoid costly accidents. 

Our MI experts have provided process safety, reliability, and risk assessment services to various production and process industries. PMET has also contributed to many industry committees addressing asset integrity issues, such as the American Petroleum Institute (API), American Society of Mechanical Engineers (ASME), National Fire Protection Association (NFPA), the American Institute of Chemical Engineers’ Center for Chemical Process Safety (CCPS) and International Institute of Ammonia Refrigeration (IIAR).

Technical Inspection and Asset Integrity Services

PMET can assist your company in developing and implementing cost-effective, technically sound, and compliant MI programs that help achieve and maintain integrity.

Owners of high-performance industrial and commercial assets, count on Pittsburgh Mineral & Environmental Technologies (PMET) to perform in-service inspection services to assess their mechanical equipment and systems’ condition, operation, and efficiency. In addition, we provide comprehensive technical inspection services for regular and/or shutdown operations and during recovery and startup operations.

We can evaluate, inspect, maintain, design, analyze and improve various types of equipment, including electronic and mechanical equipment. Our qualified engineers and professionals will work with clients to eliminate or reduce downtime for fixed and rotating equipment, instrumentation, and control systems. Our product knowledge and insight enable us to develop optimal solutions, and we work closely and in strict confidence to understand our customer’s specific needs, concerns and requirements. We also believe in the philosophy and practice of Concurrent Engineering. We can avoid costly and unnecessary revisions by early involvement with the project and work closely with our customers’ staff.

    • ASME Section VIII, Division 1, 2, and 3
    • ASME Section I and III
    • API 620
    • API 650
    • API 510
    • API 570
    • API 653
  • R-Stamp and Re-Engineering
  • Pressure / Safety Relief Valves
  • Heat Exchangers and Fin Fan Coolers
  • Columns and Towers
  • Wind / Seismic Analysis
  • Re-Rates / Alterations per NBIC and API codes
  • Safety Instrumented System (SIS) / Safety Integrity Level (SIL) Calculations and Verification
  • Rotating Equipment ITPM / PdM
  • Piping Analysis
    • ASME/ANSI B31.1 – Power piping
    • ASME/ANSI B31.3 – Chemical Plant and Petroleum Refinery Piping
    • ASME B31.G & B31.G Modified and Strength
    • API 570 Piping Systems
    • Fitness for Service

FFS (Fitness for Service) is an essential concept in process industries. FFS is the ability to demonstrate the structural integrity of an in-service component even though it contains a flaw. This serves as a rational basis for defining flaw acceptance limits and allows engineers to distinguish between benign and dangerous defects. Pittsburgh Mineral & Environmental Technologies (PMET) provides FFS for all damage mechanisms, including:

  • Fracture analysis
  • Fatigue analysis
  • Elevated temperature evaluation
  • Failure evaluation
  • Crack-like flaws
  • General and localized corrosion
  • Blisters and HIC/SOHIC damage
  • Weld misalignment and shell distortions
  • Fire damage
  • Dents, bulges, and laminations

FEA (Finite Element Analysis) is an approximation method of mathematically defining a structure’s geometry and prescribed loading (boundary conditions). We can provide a complete or partial 3D model of any structure or component. The extent of the modeling depends on the symmetrical boundary conditions. We can offer the following analyses for your assets and operations: Structural static analysis – steady-state and transient

  • Static or dynamic analysis
  • Modal analysis with harmonic response analysis
  • Transient dynamic analysis
  • Thermal analysis
  • Spectrum analysis
  • Buckling analysis
  • Linear and non-linear analysis
  • Fracture mechanics
  • Composite analysis
  • Fatigue analysis

Our welding engineers are recognized experts in adapting and developing welding procedures for new materials or to meet special project requirements. In addition, Pittsburgh Mineral & Environmental Technologies (PMET) offers a range of welding engineering and field support services, from working with clients during design and fabrication to responding to an emergency in an operating facility.

  • We can review supplier procedures and production, welding practices for quality and cost-effectiveness, develop new welding procedures, set up a job site test shop and welder training program, and train project personnel to become welding inspectors and meet the American Welding Society requirements. We also work with client suppliers to verify that specific welding procedures are followed during fabrication.
  • Our Certified Welding Inspectors can visit supplier shops to review welding procedures and confirm compliance with codes, standards, and specifications. We work with suppliers to solve manufacturing problems and help maintain production schedules without compromising quality. We also help clients evaluate subcontractor manufacturing capabilities and quality control and assurance programs.

Identifying and reducing risk at industrial facilities is a crucial management function. “How did it happen” is likely the first question senior staff and managers ask after a workplace accident. Therefore, identifying the root cause of an incident, so it does not happen again is a priority of our failure analysis professionals who work with clients to make significant improvements in system design, employee safety, and process safety, thus reducing the probability of repeated accidents.

  • We can assist in performing a damage mechanism assessment and developing corrosion control documents with informational integrity operating windows. The process starts with an overview meeting with client operations, inspection, and engineering staff to review the process operation shown on each process flow diagram (PFD).
    • The process overview will involve a detailed review of the PFD process streams to obtain the information needed to identify damage mechanisms and anticipated damage rates. Specifically, the Pittsburgh Mineral & Environmental Technologies (PMET) and client teams will identify operational and equipment history data/information such as operating conditions parameters, process stream constituents, fluid states, operating modes, failure histories, insulation conditions, and humidity areas as applicable. Also, we will identify and generate a list of equipment records and data, such as piping specifications or equipment datasheets, needed to complete the damage mechanism assessment.
    • Based on these data, our engineers will work independently to identify the damage mechanisms and anticipated damage rates to provide:
      • Set of PFDs with corrosion loops identified
      • Set of corrosion control document tables with the initial assessment of the identified damage mechanisms and anticipated damage rates
      • Integrity operating windows anticipated for each process stream
  • Resourceful people, skilled and dedicated to executing the project, are our keys to sound project management. We provide those people with appropriate project management systems to plan and forecast results. In addition, the interrelationship of our core activities and our geographical spread provides synergy and opportunities for the cross-fertilization of ideas and services.
    • The experience we have accumulated on large projects enables our project managers to combine the requirements of our clients with the logistical and technical support needed to accomplish each task, from mobilization to reporting. Moreover, due to our extensive international presence and experience, these efforts are seldom hindered by geographic location, local culture, or commercial practices.
      • Assistance with specification writing
      • Material procurement
      • Expediting materials/fabrication
      • Inspection during fabrication
      • Review of fabrication records
      • Assistance with field installation