Course 6: Mechanical Integrity

This course prepares you to evaluate your existing practices versus recognized codes and standards and then to efficiently improve or develop and implement your mechanical integrity (MI) program. Topics also include how to merge your MI program with a reliability program. To enhance the value of your training investment, plan to attend Course 6’s companion course on writing effective maintenance procedures (Course 5).


$1,100.00 USD (per student) Online

$1,100.00 USD (per student) in USA

$1,495.00 USD (per student) in Bahrain and Dubai, UAE

This course can also be taught (either as-is or customized) at your site. Please contact PII for details about having our training provided at your site.

Mechanical Integrity Course 6 (2-Day) | Process Improvement Institute

Recommended prerequisites: Participants should have practical, technical experience in maintenance of complex systems.

Typical Course Candidates

  • Designated employee responsible for designing, developing, and implementing a PSM based MI program
  • Engineers – Mechanical & Plant
  • Managers – Plant Manager, Maintenance, and Production
  • PSM Manager or Coordinators

What You Will Learn

  • Up-to-date MI strategies and techniques for effectively building and implementing a comprehensive MI program that addresses process safety management requirements and/or reliability and other concerns as defined through company, industry, and regulatory requirements
  • Through lectures and case-study-based workshops, you will learn how to develop, implement, and maintain an efficient MI program. Through thorough, step by step instruction the experienced instructor guides you through building your own MI program regardless of the age, size, or complexity of the facility
  • How to expand this program to encompass reliability and quality goals
  • How to define and assign roles and responsibilities
  • How to integrate your new or revised MI program with existing MI activities
  • Develop an inspection and testing plan using your own equipment list or generic examples
  • Quality assurance methods for identifying and resolving equipment deficiencies
  • How to develop maintenance procedures and training programs for maintenance personnel
  • Leave class with the ability to develop a maintenance procedures list for your plant site

Take Home:

  • An easily adaptable written MI program
  • A comprehensive notebook covering all course topics
  • Electronic (PDF) copy of course notebook
  • A Certificate of Completion
  • 1.3 CEUs or 1.3 COCs

Day 1 (8:00 a.m. to 5:00 p.m.)

  • Learning objectives and goals for mechanical integrity (MI)
    • Motivations for mechanical integrity
      • Regulations, standards, and interpretations
      • Relationship to Reliability programs
  • Designing a mechanical integrity program
    • Minimal MI program only for compliance?
    • Fully integrated reliability program?
    • Something in-between?
    • Workshop: Deciding in detail what you need your MI program to
      address (this sets the basis for later workshops and discussion)
  • Developing a mechanical integrity program
    • Equipment identification and related issues
      • List of critical equipment
      • Types of MI activities (reactive, proactive, preventive, predictive)
      • Choosing the right task type and choosing the specific task
      • Determining the right frequency for the task (condition or time dependent)
      • Workshop: Starting the development of an inspection, test, and preventive
        maintenance (ITPM) plan
  • Developing a mechanical integrity program (continued)
    • Personnel focus
      • Procedures
      • Training
      • Workshop: Completing the development of an IPTM plan by
        identifying written procedures and training needs for your
        mechanical integrity program

Day 2 (8:00 a.m. to 3:30 p.m.)

  • Developing a mechanical integrity program (continued)
    • Management systems required and related issues
      • Quality assurance
      • Equipment deficiency resolution
      • Root cause analysis
      • Management of change
      • Workshop: Identifying gaps in your quality assurance plan and
        identifying additional needs for procedures and training
  • Implementing/Maintaining a mechanical integrity program
    • Review of detailed checklist for implementing an MI/reliability system
    • Documenting and managing data/results, computer systems and other
      equipment files
    • Workshop: Customizing the detailed implementation checklist to
      your specific needs (optional)
  • Roles and Responsibilities for MI
  • Workshop: Identifying roles and responsibilities for your MI program
  • Key performance indicators for MI and continual improvement of a mechanical integrity program
  • Optional Exam

Bill BridgesBill Bridges will be the instructor for this course. He has taught this course many times over the past 3 years. To find out more about this course or to check into having this course taught at your site, contact Mr. Bridges at 1.865.675.3458 or by e-mail at