Process Safety Management (PSM) & Regulatory Compliance
PK Technology’s’ PSM programs provide a great value by establishing a holistic approach that enables our clients to go beyond regulatory compliance. Our programs encompass a variety of refining, petrochemical, and chemical plant assets from pressure vessels, storage tanks, and piping systems to pressure relief, vent, and emergency shutdown systems.
Our consultants advise facilities on the development of OSHA-compliant Process Safety Management (PSM) programs, review existing programs based on each facilities unique need. As stated in the PSM Standard, a robust MI program needs to impart several important factors:
- “Good Engineering Practices” need to be implemented
- The program must be developed in a procedural fashion
- Plant inspections need to be performed by certified inspection professionals
- Inspection results need to be documented and maintained in an organized fashion
- The program must meet the prevailing codes and standards available to industry
While many current MI programs are focused on predicting or preventing pressure equipment failures, PK Technology’s comprehensive and innovative mechanical integrity programs are offered as plant-wide initiatives to maximize safety and efficiency through sophisticated mobile technology.
PK Technology offers consulting expertise to aid our clients in developing, implementing, and maintaining a custom-tailored Process Safety Management (PSM) program.
Process Hazard Analysis (PHA)
PK Technology’s Process Hazard Analysis (PHA) studies are a through, systematic approach for identifying, evaluating, and controlling the hazards of processes involving highly-hazardous chemicals, as required by the Occupational Health & Safety Association (OSHA).
As companies need to perform an initial hazard evaluation on all processes covered by this standard, PK Technology’s experienced consultants have the technical expertise and industry knowledge to support them.
PK Technology helps our clients determine and digitally document the priority order for conducting PHA, based on the extent of the process hazards, the number of potentially-affected employees, the age of the process, and the operating history of the process. PHA’s must be updated and re-validated every five years.
The PHA methodology selected must be appropriate to the complexity of the process and must identify, evaluate and control the hazards involved in the process. All PHA’s must address multiple factors, including:
- Hazards of the Process
- Identification of previous incidents that had a potential for catastrophic events in the workplace
- Consequences of failure of engineering/administrative controls
- Facility siting
- Human factors
- Qualitative evaluation of a range of the possible safety/health effects on the workforce if there is a failure of controls
Once the PHA is completed, PK Technology supports our clients in addressing PHA findings/recommendations to ensure that the recommendations are resolved in a timely manner by documenting, maintaining and communicating findings to employees whose work assignments may be affected by the PHA recommendations or actions.
Integrity Operating Windows (IOWs) & Management of Change (MoC)
In addition to the requirements above, the optimal PSM program needs to include IOW and MoC programs. By offering these solutions, PK Technology enables our clients to get more value out of their PSM programs than standard regulatory compliance.
As defined in American Petroleum Institute’s (API) RP 584, integrity operating windows are established limits for process variables (parameters) that can affect the integrity of the equipment if the process operation deviates from the established limits for a predetermined length of time. In short, IOWs establish acceptable limits of process variations before an asset begins to incur damage.
MoC programs govern the documentation of changes that affect processes, such as an equipment, procedure or chemical change.
These programs are most effective when they are fully-integrated into plant operations, as changes in one process can affect another that may be overseen by a separate service provider, increasing safety risks if the proper MoC steps are not taken. This makes PK Technology uniquely-suited to support our clients in IOW program development and management.
PK Technology offers subject matter experts (SMEs) in multiple disciplines, and our inspection and maintenance services coupled with our proprietary software platform, enables our clients to stay informed when process variables become unsafe and quickly take action to reduce risks to equipment and personnel.