Case Study | Pressure Relief Analysis Get the Full Case Study AI-Accelerated Pressure Relief Analysis A Gulf Coast gas plant revalidated all 15 protected systems 40% faster in comparison to a conventional study, with 100% API 521 scenario coverage. The study found 7 inadequate relief devices, and 5 of them failed on external fire cases…
↓ Download White Paper White Paper | Process Safety Enhancing Process Safety Through a Holistic Approach to Safe Operating Limits Set operating limits only at the design boundary — or pull them straight from the PHA — and operators are left without the practical, actionable thresholds they need to act before damage occurs. Authors: Jeffrey…
↓ Download White Paper White Paper | Process Safety Enhancing Process Safety Through a Holistic Approach to Safe Operating Limits Set operating limits only at the design boundary — or pull them straight from the PHA — and operators are left without the practical, actionable thresholds they need to act before damage occurs. Authors: Jeffrey…
Technical Report | Process Safety Download Full Report The PST Gap: When Your Instruments Can’t Respond in Time A trip that activates too late — or can’t return the process to safe operation before design limits are exceeded — isn’t protection. It’s a false sense of security. Scope: Seven units across three refining facilities |…
Case StudyAlarm Rationalization for a Refinery Client: Refinery | Location: USA Cognascents is supporting a refinery with a facility-wide alarm rationalization effort aimed to improve alarm system performance, enhance operator effectiveness, and align with industry best practices. To date, the program has focused on a pilot subset of units, targeting reduction of alarm load, improvement…
Case StudyFortifying Critical PSM Program Elements for a Lithium-Ion Battery Manufacturer Client: Lithium-Ion Battery Manufacturer | Location: USA A leading EV battery manufacturer partnered with Cognascents to strengthen and harden its Process Safety Management (PSM) program. Lithium battery manufacturing involves handling flammable and reactive chemical – such as electrolyte solutions, predominantly ethyl methyl carbonate (EMC),…
Case StudyRefinery-Wide Integrity Operating Window Development Client: Refinery | Location: Oklahoma, USA Our client, a refinery operator, recognized the need to strengthen their mechanical integrity and corrosion management programs by formalizing the monitoring of key process variables that directly influence equipment degradation. Within the process units, several challenges were noted, particularly with several sour water…
Case StudyPressure Relief Device (PRD) Evaluation for Ethanol Processing Tank Project: Pressure Relief Device (PRD) Calculations Industry: Food & Beverage Location: North Carolina The Challenge A new molecular sieve surge tank and associated column system used in the production of ethanol-based specialty chemicals required evaluation to ensure adequate protection against all credible overpressure scenarios. The…
Case StudyUnderstanding & Strengthening Process Safety: A Pilot Plant Case Study in Food & Beverage Project: Pilot Plant Hazard Review Industry: Food & Beverage – Chemical Process Development Location: New York A new pilot plant was under development to convert carbon dioxide (CO₂) and hydrogen into clean fuels and specialty chemicals. The process involved high…
Case StudyCalibration of PCMS RBI Methodology for Offshore Platforms Client: Offshore Oil & Gas Operator | Location: Gulf of America A major offshore oil and gas operator was reliant on a qualitative risk-based inspection (RBI) methodology, which depended on subjective judgment and manual risk ranking. This approach led to inconsistencies in risk evaluations across similar…
