Asset Integrity Intelligence

July 2016

MECHANICAL INTEGRITY AUDIT

CHECKLIST

701 Sawdust Road., Suite #4 office +1.281.397.7075

The Woodlands, TX 77380 fax +1.281.397.9996
Mechanical Integrity Audit Checklist
Provided in partnership with Siemens Process Safety Consulting
Latest Version - July 2016

Introduction and Disclaimer

Thank you to everyone who expressed interest in and attended Inspectioneering’s webinar,
Auditing My Mechanical Integrity Program, presented by Mr. Reuben Laurel. This
checklist has been provided as a companion piece to the presentation.

Great efforts have been made to ensure reporting accuracy and quality. However,
Inspectioneering makes no express or implied warranties concerning the information
contained herein. Inspectioneering expressly disclaims all warranties, including but not
limited to, a warranty of merchantability and warranty of fitness for a particular purpose.
The data provided in this checklist is strictly for informational purposes.

How to use this checklist

If you haven’t done so already, we recommend that you watch a replay of Auditing My
Mechanical Integrity Program. To do so, Please visit: http://inspectioneering.com/
landing/auditing-my-mechanical-integrity-program-replay-and-resources

You may print a copy of this checklist or use it digitally using a PDF reader. When opened
in most common PDF reader applications, you will be able to check/uncheck each of the
boxes, type in additional notes for each section, and save your progress.

Completed By:
Start Date:
Completion Date:

Inspectioneering, LLC 701 Sawdust Road, Suite No. 4

www.inspectioneering.com

The Woodlands, TX 77380 inquiries@inspectioneering.com

MI Program Management Yes No Notes

Does your company and/or site have a

documented MI policy? ☐☐
Does your MI program have an
administrator or owner? ☐☐
Have MI roles been assigned to specific
members of your team? ☐☐
Have you clearly defined the
responsibilities associated with each role? ☐☐
The RACI model is often very helpful when assigning roles and responsibilities:
• Responsible: The person who performs the work.
• Accountable: The person who is ultimately accountable for the work completed and/or the
decisions being made.
• Consulted: Any and all people that must be consulted prior to making decisions and/or
completion of a task.
• Informed: Any and all people that must be informed when a decision is made and/or work is
completed.

Does your company and/or site have an MI

manual which sets out, among other things,
the scope and objectives of the MI ☐☐
program?
Does your MI management team have the
appropriate training? ☐☐
Does your MI program require regular, e.g.
monthly, reporting on inspection activities
that are due or past due?
☐☐
Are these reports communicated across
your entire MI team and followed up on by
management and team members?
☐☐
Does your MI program require regular, e.g.
quarterly, equipment reports that detail
needed repairs and/or replacements?
☐☐
Are these reports communicated across
your entire MI team and other appropriate
groups, e.g. engineering or maintenance?
☐☐
Does your company and/or facility have a
documented policy for addressing
equipment deficiencies?
☐☐

MI Audit Checklist Page 2

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Process Safety Management (PSM) Yes No Notes
Covered Equipment

Does your facility have a master list of all

PSM covered equipment? ☐☐
Is this list included in your MI manual? ☐☐
Does your company and/or facility have
procedures for evergreening your PSM
covered equipment master list?
☐☐
Do you have procedures for updating your
master list when your projects or
maintenance teams add, remove, or ☐☐
replace equipment?

Has a person been assigned ownership of

your master list? ☐☐
If so, who?

Notes

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Written MI Procedures Yes No Notes

Does your company and/or facility have

documented MI procedures? ☐☐
Are employees aware of these procedures? ☐☐
Are your documented MI procedures easily
accessible to all necessary personnel, e.g.
MI team members, operations, ☐☐
maintenance, etc.?
Do employees know where the procedures
are located? ☐☐
Do employees understand the applicability
of the procedures to the individual’s role? ☐☐
Does your company and/or facility have
documented Process Safety Information
(PSI)?
☐☐
Are employees aware of the PSI? ☐☐
Is your PSI easily accessible to all
necessary personnel, e.g. MI team
members, operations, maintenance, etc.?
☐☐
Do employees know the location of and
how to access the PSI? ☐☐
Does your company and/or site have a
documented policy for updating and
revalidating your MI procedures?
☐☐
Does your company and/or site have
Yes No Notes
document control policies for:

MI procedures ☐☐
PSI ☐☐
Notes

MI Audit Checklist Page 4

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MI Training Program Yes No Notes

Does your company conduct Process

Overview training for each employee
working in a process unit?
☐☐
Does this training include hazards, safety,
emergency operations, and safe work
practices that are applicable to the ☐☐
employee’s job?
Does your company conduct Process
Overview refresher training at least every
three years?
☐☐
Does your company maintain
documentation that details the processes
included in the training?
☐☐
Does your company maintain
Yes No Notes
documentation that details:

The attendees of each training ☐☐

The date of the training ☐☐
Verification that each employee understood
the training ☐☐
Does your company and/or facility have the
following requirements defined for Yes No Notes
inspectors:

Training curriculums ☐☐
Certifications ☐☐
Qualifications ☐☐
Does your company and/or facility have the
following requirements defined for Yes No Notes
maintenance technicians:

Training curriculums ☐☐
Certifications ☐☐
Qualifications ☐☐
MI Audit Checklist Page 5
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MI Training Program Yes No Notes

Does your company and/or facility maintain

documentation that details the trainings,
certifications, and qualifications of each ☐☐
inspector and maintenance technician?

Does your company and/or facility have

procedures for ensuring that each inspector
and maintenance technician renews ☐☐
certifications within required time periods?

Does your company and/or facility have

procedures for demonstration, testing, and
updating the qualifications of each ☐☐
inspector and maintenance technician?

Does your company and/or facility have

formalized MI program training? ☐☐
Does your company and/or facility have
formalized Management of Change (MOC)
training?
☐☐
Notes

MI Audit Checklist Page 6

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Inspection and Testing Yes No Notes

Does your facility have documented

inspection schedules? ☐☐
Does your company and/or facility have
documented procedures for establishing
and updating inspection schedules?
☐☐
Does each piece of equipment covered
under PSM have documentation that
includes PSI, inspection history, design and ☐☐
other relevant information?
For each inspection, is there an inspection
folder or package that includes relevant
information, e.g. PSI, NDE, drawings, ☐☐
safety, etc.?

Are your inspection procedures based on

Recognized and Generally Accepted Good
Engineering Practices (RAGAGEP),
relevant information from equipment
☐☐
manufacturers, and operating experience?

Does your company and/or facility have

documented inspection and test Yes No Notes
procedures for:

Pressure Vessels ☐☐
Storage Tanks ☐☐
Piping Systems ☐☐
Valves ☐☐
Hoses ☐☐
Relief Systems and Devices ☐☐
Does this include overhaul procedures? ☐☐
Do you have a checklist to ensure inlet and
outlet piping are inspected for pluggage? ☐☐
Pumps and Rotating Equipment ☐☐
Does this include preventative maintenance
procedures? ☐☐
MI Audit Checklist Page 7
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Inspection and Testing Yes No Notes

Does your facility maintain inspection

drawings, isometric drawings (ISOs), or
sketches that locate TMLs/CMLs?
☐☐
Does your company and/or facility have a
process for addressing thickness readings
that show growth, high corrosion rates, and
thicknesses less than the required
☐☐
minimum?

Does your company and/or facility have a

documented procedure for addressing
negative remaining life?
☐☐
For example, after taking thickness readings and calculating remaining life, it is determined that
equipment thickness dropped below minimum design thickness prior to taking the thickness readings.

In these cases, is there a procedure for

addressing when the equipment should
have been inspected in the past and what
measures should have been taken, e.g. ☐☐
fitness for services assessment or retire the
equipment?

Does your company and/or facility have

documented procedures for prioritizing
maintenance and testing of rotating ☐☐
equipment?

Do these procedures account for different

severity levels of adverse conditions? ☐☐
Does your company and/or facility have
documented inspection and loop check
procedures for all instrument loops and ☐☐
functions?

Does your company/and or facility have

documented procedures for addressing
inconsistencies between test set points ☐☐
versus what’s actually found in the field?

Has a person been assigned the

responsibility of ensuring inconsistencies
are addressed?
☐☐

MI Audit Checklist Page 8

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Inspection and Testing Yes No Notes

Does your facility have past due

inspections and/or tests for the following
equipment types:

Pressure Vessels ☐☐
If so, how many?

Storage Tanks ☐☐
If so, how many?

Piping Systems ☐☐
If so, how many?

Valves ☐☐
If so, how many?

Hoses ☐☐
If so, how many?

Relief Systems and Devices ☐☐

If so, how many?

Rotating Equipment ☐☐
If so, how many?

Does your company and/or facility have

documented procedures for managing
inspections and tests that are past due?
☐☐

MI Audit Checklist Page 9

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Inspection and Testing Yes No Notes

Have specific people been assigned the

repsonsibility of reviewing and approving:

Inspection reports and findings ☐☐

If so, who?

Test reports and findings ☐☐

If so, who?

Preventative maintenance ☐☐
If so, who?

Have these review and approval

responsibilities been included in your MI
program assignment of responsibilities?
☐☐
Does your company and/or facility have
processes in place to ensure the minimum
information required by regulators, e.g. ☐☐
OSHA, is included in documentation?

Notes

MI Audit Checklist Page 10

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Deficiencies and Repairs Yes No Notes

Does your facility have a process for

documenting equipment deficiencies, i.e.
deficiency tracking list?
☐☐
Are deficiencies tracked to completion? ☐☐
Does your company and/or facility have
procedures for removing deficiency
recommendations from the tracking list?
☐☐
Does your facility have any reported
deficiencies that were not addressed? ☐☐
Are fitness for service (FFS) assessments
performed to address deficiencies? ☐☐
If so, how are the FFS assessments
documented?

Who is responsible for managing,

performing, and documenting FFS
assessments?

Who is responsible for writing the scope of

repairs or necessary corrective actions to
restore equipment integrity?

Is the person or organization responsible

for repairs issued a work package with the
necessary PSI and other relevant ☐☐
information?

Are temporary repairs managed and

tracked to permanent repair? ☐☐
Are repairs re-inspected to verify code
compliance? ☐☐
Is risk re-assessed on repairs to determine
if further monitoring is required or
administrative or corrective action is ☐☐
necessary?

MI Audit Checklist Page 11

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Quality Assurance (QA) Yes No Notes

Does your facility have a documented QA

program? ☐☐
Does your company have QA/QC
Yes No
procedures for:

Fabrication of new vessels ☐☐

Fabrication of new piping ☐☐
Incoming materials ☐☐
Leftover materials ☐☐
Installation of new equipment ☐☐
Materials identification ☐☐
Relief devices ☐☐
Rotating equipment ☐☐
Instrumentation and controls ☐☐
Is required QA/QC performed during
During After Notes
and/or after:

Repairs ☐ ☐
Assembly ☐ ☐
Installation ☐ ☐
Notes

MI Audit Checklist Page 12

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Quality Assurance (QA) Yes No Notes

Does your company and/or facility have

standard procedures that define the
required specifications, documentation, and
information when procuring spare parts or
☐☐
replacement equipment?

Does your company and/or facility have

documented policies for managing obsolete
equipment when replacement parts cannot ☐☐
be obtained?

Are pressure vessels repaired inside of

your facility? ☐☐
Does your company and/or facility have
policies or procedures to ensure applicable
ASME section (or other applicable codes) ☐☐
compliance?

Does your company and/or facility have a

documented process for inspecting and
certifying vessels built on-site?
☐☐
If so, what is the process?

Notes

MI Audit Checklist Page 13

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