PSM Mechanical Integrity Inspection Checklist
Mechanical integrity is a key pillar of OSHA PSM. This quarterly inspection verifies that all pressure-containing and safety-critical equipment is inspected, tested, and maintained per OSHA 29 CFR 1910.119(j) requirements.
- Industry: Oil & Gas / Energy
- Frequency: Quarterly
- Estimated Time: 45-60 minutes
- Role: MI Engineer / PSM Coordinator
- Total Items: 31
- Compliance: OSHA 29 CFR 1910.119(j) - Mechanical Integrity, API 510 - Pressure Vessel Inspection Code, API 570 - Piping Inspection Code, IEC 61511 - Safety Instrumented Systems for the Process Industry Sector
MI Program Documentation
Verify MI program documentation.
- Written MI procedures covering all equipment types per OSHA 1910.119(j)(2)?
- Comprehensive equipment list covering all PSM-covered equipment?
- Inspection intervals defined per applicable API/ASME codes?
- MI database current with inspection due dates?
- No safety-critical equipment with overdue inspections?
Pressure Vessels
Review pressure vessel inspection status.
- All pressure vessels within API 510 internal/external inspection intervals?
- Thickness data current for all vessels with corrosion allowance evaluated?
- Fitness-for-service assessments completed for degraded vessels?
- Required NDE (UT, RT, PT, MT) completed per inspection plans?
- Pressure test records on file for all vessels?
Piping Systems
Review piping inspection status.
- Piping circuits documented with inspection class and TML locations?
- TML thickness readings current with corrosion rates calculated?
- Injection point inspections completed per API 570?
- Dead leg and low-flow area CMLs included and current?
- Any piping at or below minimum wall thickness replaced or scheduled?
Safety Instrumented Systems
Verify SIS testing schedule.
- All SIS loops tested at intervals maintaining required SIL per IEC 61511?
- SIS proof test records current and documented?
- All SIS bypasses authorized with alternate safeguards in place?
- SIS failures documented, investigated, and repaired per MOC?
- SIL verification current for all SIS loops?
Relief Devices
Review relief device management.
- Complete PSV inventory with test due dates maintained?
- No PSVs exceeding test interval without engineering justification?
- PSV test records with as-found and as-left pressures on file?
- PSV sizing documentation current for all installed devices?
- Rupture discs within rated service life or inspection interval?
Quality Assurance
Verify MI quality assurance program.
- All MI inspection personnel certified to applicable API standards?
- Equipment repairs performed per written repair procedures?
- Materials of construction verified before installation?
- Welders qualified per ASME Section IX?
- Quarterly MI program status report prepared?
- MI deficiency trends reviewed in annual PSM review?
Related Oil Gas Energy Checklists
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Related Process Safety Checklists
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Why Use This PSM Mechanical Integrity Inspection Checklist?
This psm mechanical integrity inspection checklist helps oil & gas / energy teams maintain compliance and operational excellence. Designed for mi engineer / psm coordinator professionals, this checklist covers 31 critical inspection points across 6 sections. Recommended frequency: quarterly.
Ensures compliance with OSHA 29 CFR 1910.119(j) - Mechanical Integrity, API 510 - Pressure Vessel Inspection Code, API 570 - Piping Inspection Code, IEC 61511 - Safety Instrumented Systems for the Process Industry Sector. Regulatory-aligned for audit readiness and inspection documentation.
Frequently Asked Questions
What does the PSM Mechanical Integrity Inspection Checklist cover?
This checklist covers 31 inspection items across 6 sections: MI Program Documentation, Pressure Vessels, Piping Systems, Safety Instrumented Systems, Relief Devices, Quality Assurance. It is designed for oil & gas / energy operations and compliance.
How often should this checklist be completed?
This checklist should be completed quarterly. Each completion takes approximately 45-60 minutes.
Who should use this PSM Mechanical Integrity Inspection Checklist?
This checklist is designed for MI Engineer / PSM Coordinator professionals in the oil & gas / energy industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.
Can I download this checklist as a PDF?
Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.