Process Safety Management

Developing optimum safety and risk management systems, guidelines and standards, and audit protocols worldwide.

A proactive approach, coupled with properly planned and implemented safety and risk management systems can help you comply with local, state and federal PSM regulations, as well as minimize loss of life, environmental impact, equipment damage, citations and litigation.

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How We Can Help You

Integrating best practices with cost-effective solutions to address program deficiencies.

Helping manage risk with facility siting studies, assessments and recommendations.

Decades of experience leading incident investigations for process industry companies.

We prepare expert opinion reports and provide expert testimony for process incident cases.

Experienced engineers who have performed LOPAs on a wide range of facilities and terminals.

Our experts are at the forefront of pipeline Process Safety Management proficiency.

Senior knowledgeable process safety engineers prepare, organize, lead and document PHAs.

Proven track record of performing QRAs for facilities, pipelines and transportation routes.

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Featured Videos


PSM Frequently Asked Questions

Does your facility need a PSM program? Is your PSM program effectively implemented?

If your facility uses, stores, manufactures, handles, or moves flammable or highly hazardous chemicals on site above the threshold quantity (TQ), OSHA does require PSM implementation. Learn the facts about process safety management.

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Our Team

Charles Lea, P.E.

Director, Minneapolis Office Lead

Mr. Lea oversees our Minneapolis office with significant experience in pressure relief and flare system design and analysis for petrochemical and chemical companies in the U.S. and overseas. He directs a number of large technical projects across multiple offices and is also responsible for all project management in our Minneapolis office. Prior to joining ioMosaic, Mr. Lea worked in the biomedical industry.

Mr. Lea specializes in pressure relief flare systems (PRFS) and effluent handling projects. He is experienced in performing complex emergency relief systems (ERS), flare, and depressurizing calculations for an array of scenarios and in the development of kinetic models from calorimetry data. Additionally, he is skilled in using chemical reactivity data and thermal analysis to complete PRFS designs for reactive systems.

Project Sampling

Analyzes pressure relief requirements using simulation software, designs relief effluent handling systems, and generates relief systems documentation.

Performed dynamic relief requirements using SuperChems™ for an alumina processing facility to determine the effects of an overpressure scenario in multiple pieces of equipment.

Evaluated risk of atmospheric dispersion for polystyrene plant. Helped the client design a flare header using existing equipment and High-Integrity Pressure-Protections Systems while providing a cost estimate to augment the existing equipment.

Performed ERS, flare and emergency depressuring calculations for multiple trains of a LNG company. Helped identify any overpressure concerns including locating areas of high acoustically induced vibration and knock-out drum analysis.

Analyzed dynamic relief requirements such as tube rupture, runaway reaction, and external fire cases where it was desired to calculated the wall temperature history.

Experience in development of kinetic models from calorimetry data.

Used chemical reactivity data and thermal analysis to complete PRFS designs for reactive systems.


Professional Engineering (PE), Minnesota 

University of Minnesota
B.S. Chemical Engineering

Featured Case Studies

Corporate Guidance On Risk Management

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 large Canadian refinery was performing risk assessments to identify personnel, environmental, and operational hazards. This work was 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.
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.

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.


Featured Services

Litigation Support

ioMosaic posesses both technical expertise and experience in the operation of plants and equipment. This background enables us to evaluate the evidence associated with accidents and determine the most probable causes, given the available information. Read more...

Emergency Relief System Design

From development of the industry’s most widely used PRFS software to serving in leadership roles on global PRFS forums, we have played a pivotal role in defining and implementing relief system best practices for corporations worldwide. Read more...

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