Starting Strong: Lessons from My First Few Months in Process Safety | Blog No. 80

On May 5th, I graduated with my degree in Chemical Engineering. One week later, I began working full-time as a process safety engineer at Macha PSM, following a five-month internship. During this time, I have been able to work on relief system calculations, vent system calculations, machinery room layouts, facility site mapping, and P&ID updates. 

The transition from being a student to becoming an engineer has revealed a few key truths about process safety; theory only scratches the surface. Field accuracy, practical applications, and understanding the system are what keep people safe.

Below are a few lessons that I’ve learned that highlight real-world challenges and priorities in process safety.

Relief System Calculations

While my classroom exercises focused on simplified, ideal relief valve sizing, real-world systems require more calculations. Since joining Macha PSM, I’ve worked on calculations that involve fire exposure, pressure drop, and multidevice venting. These systems often include heat exchangers, compressors, and suction drums. All of these pieces of equipment, and more, must be considered when looking at backpressure, frictional losses, and relief system design. Each calculation must reflect real system configurations and field-verified data, as required by OSHA’s PSM standards and the EPA’s RMP rule.

Accurate P&IDs are Foundational

One of my key responsibilities is to review and update P&IDs. It became crystal clear that these diagrams are not static documents; they evolve as the facility changes. However, most facilities operate with outdated or incomplete P&IDs, especially legacy ammonia systems. As stated in my previous blog, P&IDs are a crucial tool for a facility. Before conducting a PHA, accurate P&IDs are a non-negotiable starting point. A missing valve or mislabeled line can lead to incorrect assumptions and a flawed risk analysis.

Machinery Room Layouts and Site Maps

Site maps and machinery room drawings are not merely decorative items or optional extras; they play a crucial role in hazard communication, emergency planning, and compliance documentation. For example, site maps are essential for off-site consequence analysis. Machinery room layouts support ventilation assessments required by IIAR standards. Both documents are frequently used for training, emergency response planning, and internal audits.

Although I’ve only been working in the field for a short time, the importance of process safety is evident. Whether performing relief system calculations, reviewing ammonia PSM elements, or walking down a machinery room, each task helps prevent accidents, protect lives, and improve facility resilience.