Case Studies

Case Studies

Read examples of how ioMosaic has managed and reduced episodic risk, maintained compliance and prevented catastrophic incidents for our clients worldwide. 

Emergency Relief System Design for Portable Equipment

The Challenge

An international pharmaceutical company operates a pilot plant for new product development. Due to the changing nature of the pilot plant needs, most of the process equipment is portable and is connected to other equipment and vent headers using flexible hoses. If a relief device were to relieve, there was a concern that the equipment might move or tip over and cause personal injury and equipment damage. View case study

Benchmarking Current Industry Practices for Handling Highly Toxic Chemicals

The Challenge

An international oil company was preparing to startup a state of the art acid gas injection facility and needed to benchmark against current industry practices for handling large quantities of toxic gas at high pressure. View case study

Reactivity and Process Safety Support for Pharmaceutical Pilot Plant

The Challenge

An international pharmaceutical company has an aggressive schedule for new product development and needs technical support with respect to reactivity testing and process safety in their pilot plant. View case study

Assessment of the Impact of Loss of Critical Support Services on Safety, Environment, and Production

The Challenge

An international consumer products manufacturer suffered a significant business interruption due to failure of a critical support facility. This incident raised the question of whether there were other critical support facilities that could cause a similar interruption in production or a significant safety or environmental impact. View case study

Process Hazard Analysis of Batch Alcohol Processes

The Challenge

An international personal products manufacturer needed to complete process hazard analyses of their alcohol processes to meet regulatory and company requirements. The process hazard analyses could not be completed until all necessary process safety information was compiled. View case study

Process Safety Management Quality Audits

The Challenge

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. Traditional audit programs look at documentation and procedures, but do little to evaluate the program quality or effectiveness. View case study

Review of Preliminary Hazard Analyses for Chemical Demilitarization Options

The Challenge

Chemical weapons produced by the US military must be demilitarized by international treaty. Since some of these weapons are old, they must be demilitarized at the sites where they are currently stored to avoid potential releases during transportation. Existing technology for chemical weapon demilitarization is using incineration. However, local community concerns regarding vapor emissions required the search for alternate technologies to demilitarize chemical weapons. Three new technologies were selected for evaluation. Each new technology has its own unique safety concerns and each had to demonstrate that their technology was “as safe as incineration”. View case study

Hydrogen Fueling Safety Assessment

The Challenge

The California Energy Commission has been directed to assist in the development of clean alternate transportation fuels. As part of this effort they are supporting the commercialization of fuel cell vehicles operating on hydrogen fuel. In order to be used extensively in the transportation sector, the safety of hydrogen production, storage, and supply needs to be addressed. This will require evaluation of different alternate designs for supply of hydrogen at fueling stations. View case study

Independent Review of Risk Management Program for Proposed Plant Expansion

The Challenge

A world-class chemical company was involved in a project to triple the capacity of its fumigant plant to meet demand due to the phase-out of competing ozone depleting fumigants. The existing plant is regulated by several state and local agencies and the expansion project required permit approval in accordance with applicable laws and regulations. Certain agencies wanted an independent review of the company’s risk assessment procedures and safeguarding systems for protecting the public from operational hazards. View case study

Corporate Guidance on Risk Management

The Challenge

The chemical company of a large integrated energy company was developing a corporate standard for layer of protection analysis (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. View case study

Risk Assessments of Refinery Units

The Challenge

A large Canadian Refinery is performing risk assessments to identify personnel, environmental, and operational hazards. This work is 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. View case study

Adequacy of Hydrocracker Emergency Relief System

The Challenge

A refinery wanted to ensure that pressure relief capacity was adequate for the loss of liquid seal scenario in a high-pressure separator (2,000 psig). Also, they were concerned about the pressure waves that would occur in the high-pressure separator’s outlet lines on rapid closing of the isolation valves. View case study

Fire Exposure and Relief Protection for Vessels Containing Reactive Chemicals

The Challenge

The client was storing reactive materials in vessels that could be subject to fire exposure. They wanted to be sure that the relief protection on the vessels was correctly sized, or if not, what changes were necessary for an effective relief system. View case study

Owner/Contractor Relationships

The Challenge

As the supplier of contract labor, the client was being held responsible for the operation and safety of a chemical plant in which there was an explosion and several fatalities. View case study

Toxic Gas Release During Delivery of Chemical

The Challenge

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. View case study

Chemical Delivered into Wrong Tank

The Challenge

A supplier was being sued because his product when delivered, his product went into the wrong storage tank. This lead to a chemical reaction and release of chlorine to which the plaintiffs claimed they were exposed. View case study

Faulty Workmanship in Fabricating a Heat Exchanger

The Challenge

A heat exchanger manufacturer was being sued on a claim of poor workmanship after the heat exchanger had been in service in a plant for ten years. View case study