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Ray Wheeler
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Process Safety Management Support for a Pharmaceutical Manufacturer


A pharmaceutical client had a manufacturing facility that used an aqueous-based process that was being discontinued. In its place, a new manufacturing process utilizing flammable liquids was being considered. The facility planned to convert existing process tanks for use in blending operations in the new process. It was understood that the number of flammable liquids used in the process was to exceed 10,000 lbs. The client retained Antea Group to support its design and Process Safety Management (PSM) compliance efforts related to its manufacturing processes and to propose changes to the overall management of risks associated with exposure and flammable liquids.


Antea Group provided a virtual gap analysis of the various existing and proposed process safety management programs. This analysis considered process design and equipment information along with process safety information to provide a systematic review of risk mitigation efforts related to potential hazards that could arise out of day-to-day operations. The analyses also considered current or recommended control measures that would either prevent or mitigate the risks.


The client received a systemic and comprehensive study that helped define a pathway for future OSHA compliance (under 29 CFR 1910.119) and managing process risks. The gap analysis covered various consensus standards including documents from the National Fire Protection Association (NFPA) such as NFPA 30 that covers flammable liquids, and NFPA 77 that covers static electricity.

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Ray Wheeler
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