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Process Knowledge Management

The PSI dossier — chemistry, technology, equipment — kept current through MOC

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Strategic context

What this element is — and why it matters

Process Knowledge Management is the living dossier of everything a site needs to know about its process to operate it safely — chemical hazards, reaction kinetics, equipment ratings, P&IDs, electrical classification, relief device sizing, control logic, and operating envelopes. It maps onto OSHA PSM 1910.119(d) Process Safety Information. Bhopal, Texas City, and BP Macondo each included PSI findings in their investigations — operators making decisions on documentation that no longer matched the plant.

Individual significance for organisations

Process knowledge is the single most leveraged asset an operating organisation has. Every decision — operational, engineering, MOC, emergency response — depends on it. An organisation with accurate, accessible, current PSI operates with confidence; without it, every decision carries hidden risk. PSI quality directly correlates with PHA quality, MOC discipline, and incident-investigation depth.

Contribution to Risk Based Process Safety (RBPS)

Process Knowledge Management is the prerequisite for Hazard Identification & Risk Analysis (Element 7) — without accurate PSI, PHAs operate on bad data. It also feeds Operating Procedures (Element 8), Asset Integrity (Element 10), MOC (Element 13), and Incident Investigation (Element 17). RBPS positions PKM as the first element of Pillar 2 because every downstream risk-management activity rests on it.

Key requirements

What compliant execution looks like

Chemical hazard information per OSHA PSM (d)(1) and GHS SDS

Process technology information — block flow, PFD, P&ID, control philosophy

Equipment information — material of construction, design pressure / temperature, relief device sizing

Electrical area classification (HAC) drawings per IEC 60079 / API RP 500

Operating envelope and IOW per API RP 584

MOC discipline keeping PSI current

Implementation methodology

How we implement this element

A focused 6-step methodology calibrated to deliver process knowledge management as a working capability — not a documented compliance artefact.

PSI Inventory Baseline

Inventory required PSI per OSHA 1910.119(d) — chemical, technology, equipment; identify current state, gaps, and version control issues.

Documentation Architecture

Specify document hierarchy, naming conventions, version control, access control; integrate with EDMS (Aveva PI, Documentum, OpenText).

P&ID and PFD Refresh

Walk down P&IDs against field reality; update markups; reissue as as-built; cross-check with HAZOP / PHA records.

Equipment & Relief Data Pack

Compile equipment datasheets, MOC, MAWP, MAOP, relief device sizing per API 520/521/2000; align with mechanical integrity register.

MOC Integration

Define MOC procedure trigger for PSI update; enforce update before MOC closure; track PSI lag time as a leading KPI.

Operator Accessibility

Ensure operating teams have read access to PSI relevant to their unit; train on PSI navigation; integrate with shift handover.

Implementation flow

Element-implementation flow chart

Decision-gated workflow showing the actual sequence of activities — from initiation through steady-state operation — with key decision points highlighted.

Start

PSM owner initiates PSI baseline programme

Required PSI Inventory

OSHA 1910.119(d)(1) chemical / (d)(2) tech / (d)(3) equipment

Current-State Audit

Map existing documentation against requirement; identify gaps

Document Architecture

Hierarchy, naming, version, access — integrate with EDMS

P&ID Walk-Down

Field verification against issued P&IDs; markup as-built

Decision

Gaps Found?

Decision gate

Equipment Data Pack

Datasheets, MOC, MAWP, MAOP, relief sizing per API 520/521/2000

HAC Drawings

IEC 60079 / API RP 500 hazardous area classification

MOC Trigger Specification

PSI update enforced before MOC closure

Operator Access Verification

Read access tested; navigation training delivered

PSI Lag-Time KPI Live

Monthly dashboard tracking PSI currency vs MOC closure

Deliverables

What we produce

PSI inventory and gap register per OSHA 1910.119(d)
Document hierarchy and version-control procedure
Walked-down as-built P&ID and PFD set
Equipment / relief / HAC data pack
MOC procedure with PSI update enforcement
Operator PSI access matrix and training plan

Common pitfalls

Where execution fails

Stale P&IDs that don't reflect 10 years of modifications
Missing relief calculations for vintage equipment
MOC backlog leaving PSI register lagging reality
Operator access blocked by EDMS permission issues

Implement this element

Talk to us about implementing Process Knowledge Management

We can scope this element implementation against your facility, regulatory context, and existing management-system maturity — and integrate it with the other Risk Based Process Safety (RBPS) elements you already operate.

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