Case Study
Fortifying 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), blanketed by nitrogen. Implementing a robust PSM framework was critical to protect personnel, maintain compliance, and support the company’s rapid growth within the energy transition sector.
The client sought Cognascents’ expertise to firm up and formalize its PSM program – ensuring safe and consistent performance, closing gaps against OSHA1910.119, and supporting long-term manufacturing scalability.
Challenges
Before partnering with Cognascents, the client faced several fundamental obstacles that limited their ability to build and sustain an effective PSM program:
- Lack of Clear Framework, Resources, & Culture: The facility did not have a defined structure or dedicated personnel for managing process safety, making it difficult to establish priorities, determine where to begin, and support effective implementation.
- Compliance Gaps: Limited experience navigating OSHA 1910.119 contributed to vulnerabilities in compliance frameworks.
- Data Deficiency: Outdated or incomplete process documentation – including P&IDs and PFDs – created challenges for hazard analyses, risk assessments, and accurate MOC execution.
Our Solution, Approach, & Actions Taken
Program Development Roadmap
Cognascents collaborated with the site to develop and execute a structured roadmap to resolve deficiencies associated with critical PSM elements. More specifically, the scope focused on policy and procedure-writing, solution implementation, and risk analysis regarding the site’s Mechanical Integrity (MI), Process Hazard Analysis (PHA), and Process Safety Information (PSI) PSM elements. The team collaborated closely with operations, engineering, and PSM / EHS personnel to ensure long-term ownership and sustainability of the programmatic enhancements.
Key activities by element included:
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Process Safety Information (PSI)
Cognascents compiled and validated comprehensive PSI to support safe design and operation:
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- Heat & Material Balances: Updated H&MB to accurately reflect current design conditions.
- Maximum Intended Inventories: Defined for tanks and piping systems to support PHAs and emergency response.
- P&IDs & PFDs: Updated AutoCAD drawings based on field walk-downs and as-built conditions.
- Electrical Area Classifications (EACs): Updated and generated EACs for PSM-covered process areas – accounting for variables such as release rate, ventilation rate, area of spill and containment of release, exposure frequency, and indoor/outdoor location.
- Reactivity Matrix: Identified incompatibilities of mixing chemicals, including electrolyte solvents and cleaning agents.
- Safety Systems Inventory: Developed a comprehensive inventory of alarms, interlocks, and safeguarded systems to establish a structured framework for future alarm rationalization, prioritization, and operator response.
- Safe Operating Limits (SOLs): Established limits for key parameters such as pressures, levels, and temperatures.
- Pressure Relief Analysis (PRA)
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- The PRA provided a quantitative and semi-quantitative assessment of overpressure, fire, and release hazards—integrating findings from the PHA and relief device evaluations.
- Reviewed each unique system, including nitrogen supply, electrolyte storage, and buffer tanks, to identify credible scenarios, assess relief capacity, and confirm system integrity.
- Potential vulnerabilities included undersized fire relief cases, pocketed outlet piping, dampers not car-seal-opened, and RV discharges into cabinets that could lead to blockage or hazardous vapor accumulation.
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Process Hazard Analysis (PHA)
A comprehensive HAZOP study was facilitated for 90+ process nodes across the Central Electrolyte Storage System (CESS), buffer cabinets, and vent systems.
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- High-priority findings addressed potential loss of containment of electrolyte fluid, HF generation due to firewater exposure, and nitrogen regulator control failures.
- Identified forty-five (45) actionable recommendations, including adding interlocks, upgrading leak detection, verifying pressure relief device sizing, and enhancing SOLs.
- Final deliverables included detailed HAZOP worksheets, risk-ranking matrices, and PHA guidance documents.
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Mechanical Integrity (MI)
Cognascents built an MI framework to facilitate continuous reliability and regulatory compliance:
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- Conducted and reviewed an MI audit checklist to ensure the program could be effectively implemented.
- Defined inspection and testing frequencies based on risk and service.
Overall, Cognascents collaborated closely with client personnel and third parties to develop a complete MI documentation suite tailored to their framework, which included – but was not limited to – an asset register, inspection criteria documents, MI policies with defined roles / responsibilities, and vendor inspection requirements.
Big Picture Impact & Lessons Learned
Cognascents delivered core PSM program elements – including PHA and PRA reports, PSI documentation, defined SOLs, and MI procedures – improving the facility’s PSM maturity within five months.
Some key lessons to take away:
- Financially supporting PSM is essential. Integrating process safety early in design and budgeting for the management of change prevents costly retrofits and reduces long-term liability.
- Put people first. Although only the PHA included a workshop session, we maintained strong collaboration through the PRA and entire engagement through weekly/bi-weekly touchpoints and rapid responses to client needs, reinforcing that we are partners in their success.
The program established a foundation for continuous improvement and operational excellence, positioning the manufacturer as a process safety leader in the EV battery sector—a critical achievement in an industry balancing innovation and safety.
Related Cognascents Solutions
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