A polystyrene production facility wanted a complete audit of all pressure relief valve files and documents to determine any 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.
ioMosaic PRFS analysis and audit was performed using our software Process Safety Office® SuperChems™ to analyze the process safety data and identify potential deviations. The scope of work included all relief devices and associated protected equipment, classified by client personnel to be PSM-covered and non-PSM-covered. This project also determined the adequacy of the effluent handling system serving the facility based on the relief systems as-installed and controlling global scenario(s).
This project involved an extensive amount of process safety data. ioMosaic utilized our information management solution Process Safety Enterprise® to manage, track, and securely share all process safety data with the client's team. Each of the 189 systems in the operating unit that required analysis received from ioMosaic a detailed report, an overpressure scenario report, and a specification sheet. These records served as the official, as-built relief system design basis. The client could now access anytime a secure database containing all relevant documentation, specification sheets, summary information, and so on for the devices and associated equipment at their facility.
ioMosaic highlighted for the client 356 items of concern, delivering a detailed list of potential deviations from industry codes, standards, RAGAGEP, and client corporate guidelines. This list, along with initial discussions of potential mitigation options for each item, was shared with the client's process safety management and operations groups. As a result of the detailed baseline revalidation study, subsequent projects have been discussed to resolve the identified deviations. The client now has peace of mind.