We provide a number of Process Safety (PSM) services to our refinery and chemical manufacturing clients. Many customers, not only need in depth support to develop operating procedures to run their units in a consistent manner, ask for help developing Inspection, Testing, Preventative Maintenance (ITPM) for the equipment in their facility. Our team of engineers, former operators, and other technical professionals has acted as an owner-agent to build a grassroots Mechanical Integrity program. This included reviewing P&IDs to determine PSM covered processes, developed equipment lists, located missing Original Equipment Manual (OEMs), identified applicable Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs), and draft all regulatory required procedures to meet full compliance with 29 CFR 1910.119.
Upon completion of procedure development, our team worked with the facility(ies) to draft Management of Change Documents that provided the maintenance department with the flexibility to manage day-to-day maintenance challenges while maintaining full compliance with the standard. We also worked with the team to understand the resources needed to fully execute the formalized maintenance requirements. During the resourcing evaluation portion of the project, an estimated $600,000 per year was saved in labor costs and the maintenance department was fully resourced to conduct the necessary facility maintenance activities. In addition to the substantial annual cost savings, the facility now uses the program as a cornerstone of day-to-day plant operations.