Process Safety Consulting

Conversion Technology, Inc. (CTI) offers Process Hazard Analysis, Program Audits and Inspections, Consulting, Program Development, and Training to industrial facilities in accordance with 29 CFR 1910.119 and 40 CFR Part 68. These services are designed to keep your employees safe, while complying with OSHA’s Process Safety Management of Highly Hazardous & Explosive Chemicals and EPA’s Risk Management Program regulations.

PSM and RMP Program Development
Process Hazard Analysis
Consequence Analysis Modeling
PSM and RMP Audit and Compliance Review
Training and Implementation

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PSM and RMP Program Development

Both OSHA and EPA have specific requirements for written programs and procedures under the PSM and RMP programs. We have decades of experience in preparing comprehensive Process Safety and Risk Management systems that can be effectively used by facilities to comply with all the necessary regulations. This includes preparing the written plans, procedures, guidelines, and reports needed to implement your RMP and PSM program. Specifically, for PSM programs, the required elements include:

  • Employee Participation
  • Process Safety Information
  • Process Hazard Analysis
  • Operating Procedures
  • Training
  • Contractors
  • Pre-Startup Safety Review
  • Mechanical Integrity
  • Hot Work Permit
  • Management of Change
  • Incident Investigation
  • Emergency Planning and Response
  • Compliance Audits
  • Trade Secrets

Process Hazard Analysis

In order to efficiently and effectively minimize the risks associated with a process, you must fully understand its hazards. A Process Hazard Analysis (PHA) is used to systematically identify the hazards and evaluate their causes and consequences in order to assess the level of risk and adequacy of the current safeguards. CTI’s chemical and mechanical engineers have the knowledge and experience to facilitate the Process Hazard Analysis (PHA) for your facility, including providing prioritized recommendations designed to reduce risk. We can:

  • Conduct initial PHA and 5 year PHA Revalidation using
  • Hazard and Operability (HAZOP) studies
  • Failure Mode and Effects Analysis (FMEA)
  • What If / Checklist
  • Layers of Protection Analysis (LOPA)
  • Conduct PHA with Management of Change (MOC)

Consequence Analysis Modeling

Process safety is just as important onsite for employees and offsite for civilians. OSHA and EPA have requirements for accidental releases of toxic gas plumes, fires, and explosions to ensure there is a proper safety plan. For every offsite consequence analysis (OCA) component of the risk management plant (RMP), a worst-case and alternative release scenario must be included. This should cover toxic and flammable regulated chemicals held above the threshold quantity. The OCA needs to be revised anytime a change in the facility results in the distance to an endpoint from a worst-case release changing by a factor of two or more. We can aid in developing the consequence analysis by:

  • Modeling gas plume dispersions and the toxic concentrations around the facility
  • Modeling fires (both chemical and non-chemical) and the smoke plumes associated with it to give the heat radiation in the surrounding area
  • Modeling explosions and determining the damage from the overpressure wave
  • Recommending potential evacuation routes based on the damages from the accidental releases
  • Calculating the lethality and structural damage caused by an accidental release

PSM and RMP Audit and Compliance Review

Conversion Technology, Inc. (CTI) has decades of experience with process safety, allowing us to be familiar with the hazards and risks associated with your processes, as well as the methods needed to control the hazards. Like all management systems, your Process Safety Management (PSM) and Risk Management Programs (RMP) need to be audited to ensure they are current, adequate, and properly implemented. The PSM standard requires compliance audits every 3 years. The compliance audit requires a thorough review of the documentation and PSM program, including: employee interviews, review of the covered system(s), Management of Change (MOC) practices, Process Hazard Analysis (PHA), and P&IDs/flow diagrams. We are available to:

  • Conduct the required 3 year PSM program audits.
  • Evaluate compliance with OSHA’s PSM and EPA’s RMP standards, including focusing on OSHA’s PSM
  • Covered Chemical Facilities National Emphasis Program (NEP)

Training and Implementation

Once the PSM and RMP systems have been established, it is important for plant personnel to be knowledgeable of the hazards they are exposed to and their roles in process safety. We are available to provide site specific training for all level of employees and offer assistance in the implementation of your programs. CTI is available to:

  • Lead PSM Team development
  • Develop site-specific training for employees
  • Present educational training for engineers and managers
  • Assist in the implementation of the PSM and RMP programs and policies

Process Safety Consulting Services