An international pharmaceutical company had an aggressive schedule for new product development and needed technical support with respect to chemical reactivity testing and process safety in their pilot plant.
When materials of interest are new or unknown, characterization of chemical reactivity hazards is best done by experiment. We provided the client an overall process for conducting reactivity testing in the form of a six best-practices type; simple, practical and easy to use documents with examples. Included in these documents were a number of practical tools consisting of public-domain software, our spreadsheets, and user licenses for PSMPro™ software to conduct hazard analysis from our exclusive partner ioMosaic Corporation. We also provided training to assist in the implementation of each of the associated tools. PSMPro™ has very user-friendly tools that take very little time to master. The pre-populated templates include Hazard and Operability (HAZOP), What-if?, LOPA, FMEA, and Checklist (including Facility Siting and Human Factors). These templates are available in English, Spanish, and Portuguese. Includes the ability to customize the risk matrix based on your risk ranking criteria, including the ability to add an unlimited amount of consequence and frequency levels.
Identifying hazards is a required evaluation for Process Hazard Analyses (PHAs) studies. The ioKinetic team helped the client to identify the chemical reactivity hazards of their product using best practice reactivity screening techniques. We also helped them understand the requirements for compliance with global industry standards. Formal training for all internal PHA leaders companywide ensured the quality of their PHAs from site to site, therefore optimizing their process safety. They learned to question the design of a system and not make assumptions. They also learned the importance of being unbiased to ensure a process is evaluated with a critical eye for safety.