A proactive approach, coupled with properly planned and implemented safety and risk management systems can help you comply with local, state and federal PSM regulations, as well as minimize loss of life, environmental impact, equipment damage, citations and litigation.
ioMosaic pioneered many of the current risk assessment techniques for processes that handle hazardous chemicals.
Our experts support every aspect to ensure that your facility runs safely and efficiently.
Expertise to help you minimize your exposure to fire, injury, property damage, and litigation.
Integrating best practices with cost-effective solutions to address program deficiencies.
Helping manage risk with facility siting studies, assessments and recommendations.
Senior knowledgeable engineers facilitate hazard analyses in nearly all sectors of the process and processing industries.
Decades of experience leading incident investigations for process industry companies.
We prepare expert opinion reports and provide expert testimony for process incident cases.
Experienced engineers who have performed LOPAs on a wide range of facilities and terminals.
Our experts are at the forefront of pipeline Process Safety Management proficiency.
Proven track record of performing QRAs for facilities, pipelines and transportation routes.
Well versed in assisting global companies with their sustainability reporting communications.
Decades of experience mitigating hazards for the chemical and pharmaceutical industries.
A global specialty chemicals company that is known for manufacturing ingredients used in pharmaceuticals, personal care products, nutrition, agriculture, and sectors impacted by green technologies, needed an in-depth evaluation of its chlorine handling operations against specific standards. Read the case study and learn the advantages of working with ioMosaic.
A group of concerned property owners enlisted the help of ioMosaic to provide engineering support in their case against the proposed location of a Battery Energy Storage System (BESS) facility. The client needed to demonstrate that the risk posed by locating the facility in close proximity was unacceptable to the surrounding community.
In accordance with OSHA PSM regulations, a global manufacturer of industrial gas needed to revalidate their Process Hazard Analysis (PHA). This PHA study focused on identifying any significant safety and environmental impacts associated with the facility's liquid nitrogen / gaseous nitrogen system, and the gas, monitoring, and ventilation system.
If your facility uses, stores, manufactures, handles, or moves flammable or highly hazardous chemicals on site above the threshold quantity (TQ), OSHA does require PSM implementation. Learn the facts about process safety management.
Today, the process industries need to be certain that their stakeholders have confidence in how they manage the environmental, health, security, and safety implications of industrial activities. Read this white paper for a systematic, risk-based approach to safe design that can help to eliminate hazards that pose high risks from the process and help mitigate.
A chemical incident doesn’t care whether a facility triggers OSHA Process Safety Management (PSM) thresholds. For small-to-mid-sized operations or distilleries, handling hazardous materials—even in small quantities—carries a disproportionate risk. While they may technically escape the heavy administrative burden of OSHA 29 CFR 1910.119 or the EPA’s RMP, a single process failure can still result in catastrophic injury, devastating property loss, and business-ending liabilities. Furthermore, "exempt" does not mean "unregulated." Smaller facilities are still strictly bound by other OSHA standards, laboratory safety codes, and aggressive state and local fire regulations.
Building a robust process safety program with limited resources can feel daunting, but it is entirely achievable. This white paper introduces a scalable, practical process safety framework designed specifically for facilities not subject to federal PSM/RMP mandates. The ioMosaic miniPSMSM approach demonstrates how process safety can be implemented by smaller companies over time. This framework provides a universal roadmap to proactively mitigate risk, protect the workforce, and safeguard company’s bottom line.
A dangerous myth quietly circulates among small and mid-sized operations: “If we don’t meet the OSHA PSM threshold, we don’t have a process safety problem.” Many facility managers operate under the false assumption that because they don't handle massive, railcar-level quantities of highly hazardous chemicals, their processes are inherently safe.
History tells a radically different—and devastating—story.
Chemistry does not respect regulatory boundaries. A runaway reaction, a vapor cloud ignition, or a pressurized system failure is just as lethal at a local small-batch facility as it is at a massive petrochemical plant. In fact, smaller facilities are often more vulnerable because they lack the deeply integrated safety layers mandated by federal law. To understand how easily a standard workday can turn into a catastrophic headline, one only needs to look at four tragic incidents where facilities operating completely outside the mandate of OSHA PSM suffered devastating consequences:
Sep 4, 2026
Jul 13, 2026
May 29, 2026