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

Our experts support every aspect to ensure that your facility runs safely and efficiently.

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 engineers prepare, organize, lead and document PHAs remotely or onsite.

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

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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

Georges A. Melhem, Ph.D., FAIChE

President & CEO The founder of ioMosaic and internationally renowned expert in the areas of pressure relief and flare systems design, chemical reaction systems, process safety and risk analysis. Read more...

Neil Prophet

Senior Vice President and Partner Pressure relief and flare systems design project management and engineering expertise for chemical, pharmaceutical and petrochemical companies. Read more...

Daniel Nguyen, PE & PMP

Senior Vice President and Partner Responsible for a team of software engineers in the development of ioMosaic’s PSO software and manages pressure relief and flare systems evaluation and design projects. Read more...

Katherine Anderson, CCPSC

Principal Consultant Experienced project leader in hazard identification, evaluation, functional safety, process safety and risk management. Read more...

John Barker, Ph.D.

Director The Director of our U.K. office and an expert in risk management for the international oil and gas and transportation industries. Read more...

Marcel Amorós-Martí

Director, California Office Lead His expertise includes pressure relief and flare systems design for large chemical and petrochemical companies around the globe and in the United States. Read more...

Charles Lea, P.E.

Director, Minneapolis Office Lead He directs a number of large technical projects across multiple offices and is also responsible for all project management in our Minneapolis office. Read more...

Pamela M. Nelson, CCPSC

PSM Consultant She leads process safety projects for business units across the U.S., Canada, Thailand, China, and the U.K. Read more...

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.
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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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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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Featured Resources

Leveraging Existing Management Systems to Comply with both cGMP and Process Safety Requirements

cGMP regulations protect people and animals from the adulteration of food and drugs that makes the product impure, unsafe, or unwholesome. This paper compares the key elements from the U.S. PSM requirements from 29 CFR 1910.119 with the International Conference on Harmonization (ICH) Q7 which is cGMP for Active Pharmaceutical Ingredients (APIs). 

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Quantify Explosion Venting Dynamics in Vessels Enclosures and Energy Storage Systems

Explosions can occur in vessels or enclosures containing flammable gases and/or dusts. Explosion venting, often referred to as deflagration venting (because we cannot practically vent detonations), is used to protect from catastrophic vessel/enclosure failure. Simplified equations are often used to determine the deflagration relief requirements. Simplified equations can be found in standards such as NFPA-68 [1]. While easy to use, simplified equations tend to overestimate the relief requirements and have several practical limitations.

Simplified equations provided in NFPA-68 [1] require the use of an explosion severity index, usually obtained from actual testing in a 20 liter sphere or a 1 m3 vessel. Published severity index data for flammable gases or dusts are also used. Typically, simplified equations for deflagration venting apply to ideal geometries and for short vent lines. They are not readily applicable to complex geometries, systems with elevated initial temperatures or pressures, hybrid systems containing flammable gases and dusts, systems with diluents and/or chemical oxidizers, systems with reduced venting set pressures, geometries with long L/D ratios or geometries with long vent piping where flame acceleration becomes significant.

We have developed detailed deflagration and explosion dynamics methods and computer codes that address many of the shortcomings of simplified sizing methods. These dynamic methods rely on a detailed representation of all possible independent combustion reaction(s) using direct Gibbs free energy minimization [2, 3, 4] coupled with a detailed burning rate model developed from measured explosion data using a 20 liter sphere or a 1 m3 vessel. We describe these methods in what follows and provide examples of how they are applied and how the burning rate models are developed from measured data.


Featured Services

Process Hazard Analysis

Senior knowledgeable process safety engineers prepare, organize, lead and document PHAs remotely or onsite. Read more...

Asset Integrity Management

Our experts support every aspect to ensure that your facility runs safely and efficiently to maximize the lifecycle and reliability of your assets. Read more...

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