Condition Monitoring for Chemical Processing

Where OSHA PSM, EPA RMP, DOT Hazmat requires documented preventive maintenance and equipment condition tracking, Condition Monitoring data provides the audit-ready evidence. Measurements traceable to ISO 17359 and ISO 13374, calibrated instrumentation records, written procedures, and finding-to-work-order tie-back. The program isn't structured to be a compliance tool — but the data it generates as a byproduct usually closes 60-80% of an inspector's questions about equipment condition.

Site walk to scope the asset population, criticality scoring of the seal integrity, exchanger tube reliability, reactor uptime, baseline measurements on the top 30-60 assets, then a regular cycle of monthly on critical, quarterly on B-criticality. Findings get written up against ISO 17359 and ISO 13374. For Reliability Consulting for Chemical Processing Plants facilities the engagement usually includes coordination with the plant's existing compliance program — pulling Condition Monitoring results into the OSHA PSM, EPA RMP, DOT Hazmat audit file. Initial scope runs $15K-$45K depending on asset count, then ongoing at $180-$300 per asset per month.

Run the math against $15K-$80K/hour for continuous process for downtime cost. A single avoided unplanned shutdown on a critical asset usually pays for six to twelve months of program cost. Most Chemical Processing sites we work with see 3:1 to 6:1 program ROI inside year one, with higher figures at sites with higher hourly downtime costs. Sites with very high downtime costs ($100K/hr+ in some Chemical Processing operations) can see 10:1 or better.

Where OSHA PSM, EPA RMP, DOT Hazmat requires documented preventive maintenance and equipment condition tracking, Condition Monitoring data provides the audit-ready evidence. Measurements traceable to ISO 17359 and ISO 13374, calibrated instrumentation records, written procedures, and finding-to-work-order tie-back. The program isn't structured to be a compliance tool — but the data it generates as a byproduct usually closes 60 to 80 percent of an inspector's questions about equipment condition.