Asset Integrity (also referred to as Mechanical Integrity) findings remain on top of OSHA’s citation list during PSM inspections. Violations most frequently found include failure to address equipment deficiencies, lack of AI written procedures, and failure to perform internal AI inspection(s) and test performance. Establishing systems to collect equipment information to develop proper, effective AI procedures that maintain equipment integrity, schedule inspections, and track deficiency resolutions are a major challenge – especially for smaller companies. Like process design, asset integrity is critical to the safe operations of facilities. Its criticality is demonstrated by the fact that it is one of the 14 elements of the OSHA PSM standard as well as a pillar of the risk management foundation in the risk-based process safety management system. Its implementation is a challenge for companies of all sizes but becomes very hard for smaller facilities with minimal resources. An effective AI program requires a large amount of effort and resources not only to set-up the initial program but also to execute the inspection schedules on time and address any recommendations / deficiencies that were identified. This paper identifies how three key components: electronic database management, proper information collection practices, and the use of workflows to track inspection and deficiency status, can greatly improve the efficiency of an AI program.
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