Case Studies

Read how ioMosaic has reduced process safety risk, maintained compliance and substantially increased peace of mind for our clients worldwide.

 

Process Safety Management

An international consumer products manufacturer suffered a significant business interruption due to failure of a critical support facility. This incident raised the question of whether there were other critical support facilities that could cause a similar interruption in production or a significant safety or environmental impact.

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An international oil company was preparing to startup a state of the art acid gas injection facility and needed to benchmark against current industry practices for handling large quantities of toxic gas at high pressure.

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A supplier was being sued because his product, when delivered, went into the wrong storage tank. This led to a chemical reaction and release of chlorine to which the plaintiffs claimed they were exposed.

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The chemical company of a large integrated energy company was developing a corporate standard for LOPA, which incorporated a risk ranking matrix. The company was interested in obtaining an independent review of the design of the risk matrix, and in benchmarking the underlying risk tolerability criteria with generally accepted industry norms.
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A major oil refinery needed to ensure the adequacy of several Emergency Depressuring Systems (EDS) within their operating process units. The client requested ioMosaic evaluate the dynamics of all interlinked equipment during depressurization and to verify that the EDS is capable of reducing the system pressure.
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The client was experiencing disruptions that were causing significant facility downtime and expense. The facility also had experienced deflagrations originating from various other parts of their facility. The client believed that their expensive, custom-made square rupture disks were prematurely rupturing on their blowing stills and their knockout boxes because they were incorrectly specified.
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A world-class chemical company was involved in a project to triple the capacity of its fumigant plant to meet demand due to the phase-out of competing ozone depleting fumigants. The existing plant is regulated by several state and local agencies and the expansion project required permit approval in accordance with applicable laws and regulations.
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As the supplier of contract labor, the client was being held responsible for the operation and safety of a chemical plant in which there was an explosion and several fatalities.
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An international personal products manufacturer needed to complete process hazard analyses of their alcohol processes to meet regulatory and company requirements. The process hazard analyses could not be completed until all necessary process safety information was compiled.

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A leading chemical supplier relocated their microbiology and environmental labs from one location to another one in 2008. A PHA was conducted when the labs were set up. The client wanted to have a revalidation of that PHA by conducting a new PHA to review the basic design and practices. Specifically, this new PHA study focused on conceptually identifying any hazards associated with the labs from the point of view of general housekeeping, emergency equipment, piping, electrical, and ergonomics which could have direct impacts on the people, environment, property, and/ or public relations.
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Companies have implemented their process safety management programs to comply with OSHA and EPA requirements, but they continue to have accidents. Process safety management programs can meet the letter of the law, but may not be effective in preventing accidents.

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A client needed to update a prior QRA study from 2015 of their plant with more equipment and buildings. OSHA 29 CFR 1910.119 PSM requires, under the Process Hazard Analysis (PHA) element, that employers conduct a facility siting study to verify that the location and occupancy of buildings, control rooms and trailers have been properly evaluated.
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Chemical weapons produced by the US military must be demilitarized by international treaty. Since some of these weapons are old, they must be demilitarized at the sites where they are currently stored to avoid potential releases during transportation. Existing technology for chemical weapon demilitarization is using incineration.

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A large Canadian refinery is performing risk assessments to identify personnel, environmental, and operational hazards. This work is being done on a planned schedule with a different unit being reviewed annually. The challenge was to use Process Hazard Analysis (PHA) methodologies that provide an effective analysis appropriate to the unit to be studied and the potential hazards.
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When a tank car failed at a customer’s plant, a release of toxic gas occurred. Our client, the supplier of the chemical, was the subject of a class action lawsuit.
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Emergency Relief Systems Design

A refinery approached ioMosaic for the purposes of ensuring that pressure relief capacity was adequate for the loss of liquid seal scenario in a high-pressure separator (2,000 psig). They were also concerned about the pressure waves that would occur in the high-pressure separator’s outlet lines on rapid closing of the isolation valves and sought our expertise.
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A large oil refinery with a very complex flare network had become so complex that the tools the refinery was using to evaluate the flows through the flare network could not adequately model the system. Management no longer had confidence that their model results reflected the actual network performance and therefore, could not be sure the system would perform properly in the event of a global relief scenario at the facility.
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An international pharmaceutical company operates a pilot plant for new product development. Due to the changing nature of the pilot plant needs, most of the process equipment is portable and is connected to other equipment and vent headers using flexible hoses.

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A multinational energy company wanted to complete an evaluation of a PRV system in order to comply with the PSM standard OSHA 29 CFR 1910.119 which requires that employers compile information pertaining to the equipment in the process, including relief system design and design basis. 
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As a result of recent industrial incidents, a petroleum company desired to ensure the effluent from all relief devices in toxic or flammable service were routed to flares and/or another safe locations. The client wanted to evaluate the adequacy of the existing flare systems with the effluent from the atmospheric relief valves included, mitigate all existing flare systems issues, estimate the cost associated with modified piping, and evaluate potential high-integrity protection systems (HIPS).
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A heat exchanger manufacturer was being sued on a claim of poor workmanship after the heat exchanger had been in service in a plant for ten years.
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The client was storing reactive materials in vessels that could be subject to fire exposure. They wanted to be sure that the relief protection on the vessels was correctly sized, or if not, what changes were necessary for an effective relief system.

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An LNG manufacturer had four nearly identical trains with three flare header systems. The client decided they wanted to use a new and more stringent criteria than previously performed under a different design criterion. The large scope and tedious nature of the data entry was a challenge since all calculations needed to be checked to determine the maximum pressure each flare pipe line would be exposed to.
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An independent company executed a large capital project that included expansion and modification of one of their process units. The client required an update to existing flare analysis, which ioMosaic had previously completed, with the global scenario information from the capital project.

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A new peroxide injection system for use in the production of poly olefins was being tested. Six different peroxides were being evaluated for use in the process. An on-site engineering and construction firm retained ioMosaic to complete an evaluation of the peroxide storage vessels to ensure compliance with the PSM standard.
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A polystyrene production facility wanted a complete audit of all pressure relief valve files and documents to determine and process safety information gaps. Requirements included analyzing a third-party contractor’s evaluation of specific vessels that did not have a relief device installed on them, and a pressure relief and flare system design evaluation on the relief devices at the facility.
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An oil and gas company retained ioMosaic to complete a stability evaluation of six pressure relief valve (PRVs) that were identified to have inlet pressure drop in excess of 3% of the set pressure to ensure compliance with the PSM standard.
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An international oil and gas company requested ioMosaic perform a relief system revalidation of the DHT at a feed rate of 60,000 bbls/day in a previous assignment. The client desired to increase unit throughput to 78,000 bbls/day or higher and thus ioMosaic evaluated the relief safety at 92,000 bbls/day.
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Previously, a multinational energy company requested ioMosaic perform a relief system revalidation of two crude desalter units at a throughput of 135,000 bbls/day. Now the client desired to evaluate the capacity and stability of the two desalter valves at a new flowrate of 165,000 bbls/day with different feedstocks. Electrostatic desalters are commonly used to separate water, salt and other impurities from crude oil emulsions.
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LNG Risk Management

An incident at a gas processing plant centered around the loss of liquid level and breakthrough of a high pressure two-phase mixture into low pressure equipment (HP/LP Interface) leading to cold temperatures and subsequent brittle failure of a vessel. The case team needed to confirm or rule out operator actions that could have led to the incident. The individual events and actions that lead to the incident happened over a period of several hours. The process was so complex that careful study by many experts was unable to clearly identify the cause-and-effect of each of the events and actions.

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An LNG manufacturer had four nearly identical trains with three flare header systems. The client decided they wanted to use a new and more stringent criteria than previously performed under a different design criterion. The large scope and tedious nature of the data entry was a challenge since all calculations needed to be checked to determine the maximum pressure each flare pipe line would be exposed to.
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The California Energy Commission had been directed to assist in the development of clean alternate transportation fuels. As part of this effort they are supporting the commercialization of fuel cell vehicles operating on hydrogen fuel. In order to be used extensively in the transportation sector, the safety of hydrogen production, storage, and supply needs to be addressed.

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Laboratory Testing

An international pharmaceutical company has an aggressive schedule for new product development and needs technical support with respect to reactivity testing and process safety in their pilot plant.
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