Chemicals & specialty chemicals
Toxic and reactive materials, batch operations, multipurpose equipment and frequent product changes.
- Reactive chemistry and runaway reactions
- Batch procedure errors and mischarging
- Toxic releases affecting workers and neighbors
- Frequent changes stressing MOC
Petroleum refining & petrochemicals
Large flammable inventories at high temperature and pressure, complex units and aging infrastructure.
- Loss of containment from corrosion and damage mechanisms
- Vapor cloud explosions and building siting
- Relief and flare system capacity after debottlenecking
- Turnaround startups and shutdowns
Oil & gas, midstream & pipelines
Gathering, processing, compression and transport of hydrocarbons, often across remote and distributed sites.
- High-pressure gas releases and jet fires
- Remote operations and limited staffing
- Pipeline station and terminal overfill
- Hydrogen sulfide exposure
Power generation & energy transition
Combustion, gasification, hydrogen, ammonia and carbon capture technologies bring process-industry hazards into the power sector.
- Fuel gas, hydrogen and syngas fire and explosion hazards
- Ammonia and amine systems in emissions control and carbon capture
- Burner management and combustion safeguards
- Novel technologies with limited operating history
Pharmaceuticals & life sciences
Solvent handling, powders, potent compounds and reactive chemistry in regulated manufacturing.
- Combustible and potent powders
- Flammable solvent vapors and electrostatic ignition
- Reaction scale-up hazards
- Aligning process safety with cGMP change control
Food, beverage & ammonia refrigeration
Anhydrous ammonia refrigeration systems, combustible food dusts and thermal processing.
- Ammonia releases in occupied and populated areas
- PSM and RMP compliance for refrigeration systems
- Combustible dust in sugar, flour, starch and grain handling
- Mechanical integrity under IIAR standards
Government & defense facilities
Facilities handling hazardous and energetic materials under rigorous federal oversight.
- Highly toxic materials requiring stringent containment
- Complex regulatory and permitting frameworks
- High levels of documentation and review
- Startup and closure of first-of-a-kind facilities
Terminals, storage & distribution
Bulk storage and transfer of flammable and toxic liquids and gases.
- Tank overfill and vapor cloud formation
- Truck, rail and marine transfer operations
- Atmospheric tank venting and relief
- Emergency response planning
General & advanced manufacturing
Processes using flammable gases, solvents, combustible metal and polymer dusts, and specialty chemicals.
- Combustible dust in dust collectors and conveying
- Flammable gas systems and furnaces
- Chemical storage and compatibility
- Programs for facilities new to PSM