2025 PCMS® User Group Meeting

PCMS Enhancements Track

Introducing Enhanced Consequence of Failure Calculations in PCMS

We are excited to announce a significant upgrade to our PCMS software with the integration of the latest API RP 581 Fourth Edition Level 1 Consequence of Failure (CoF) calculations. This enhancement marks a transformative shift from our previous approach, offering our clients a more precise and comprehensive understanding of the potential impacts of loss of containment (LoC) events.

Previous Approach: Financial Focus

Traditionally, PCMS expressed CoF solely in financial terms, calculating production loss, environmental consequences, and health & safety impacts. This method relied on categorizing the impact per chemical in the process stream and using RAGEGAP lookup tables to assign a financial value to each area. While conservative, this approach leans more toward a qualitative assessment, providing a general estimation rather than specific insights.

New Approach: Detailed and Scenario-Specific Calculations

The new CoF calculations in API RP 581 Fourth Edition utilize more discreet models to determine the expected release mass of the product and its effects on the surrounding environment, people, and equipment. By calculating both a consequence area and a financial consequence, this method offers a better indication of the impact of an LoC event. Each scenario is evaluated individually, providing specific calculations that enhance accuracy while maintaining conservative estimations.

Key Benefits for Users

1. Enhanced Understanding: Clients will gain a deeper insight into the CoF for each LoC event, with both financial and area consequences clearly outlined. This dual approach ensures a comprehensive view of potential harm to people and the environment.
2. Duty of Care: The Area CoF calculation allows clients to better demonstrate their duty of care, showcasing their commitment to safety and environmental protection. This is beneficial across all industries.
3. Improved Decision-Making: With more accurate and detailed CoF calculations, clients can make better-informed decisions regarding risk management and mitigation strategies.

Seamless Integration and User-Friendly Interface

The integration of the new CoF calculations into PCMS required only minor adjustments to the interface. With 90% of the necessary data already captured in PCMS, clients will find the transition smooth and intuitive. Additional fields have been incorporated to accommodate the new calculations, ensuring that all required inputs are easily accessible.

PCMS Best Practices Track

PCMS 9.5 Best Practices: Get Ahead of the Data

Don't just maintain your system—maximize it by unlocking the full potential of PCMS 9.5. This session is designed to turn insight into action.

Led by PCMS SMEs who train and support facilities across the industry, you will learn how your peers are optimizing their programs, see real-world examples, and get your implementation questions answered. Whether you're fine-tuning your current setup or planning a rollout, you'll leave with ideas and techniques you can apply immediately.

Your data is your strongest asset…if you know how to use it. We will show you how to uncover inconsistencies, correct anomalies, and turn your inspection data into a clear, actionable story. It’s all about working smarter, staying ahead of the curve, and building a program that works for you.

What You’ll Explore:

• Discover how the IOW Process Historian Link connects real-time process data with integrity thresholds—so you can detect issues before they impact reliability.
• You'll learn how to build robust Filters that cut through data noise, launch those filters directly from your ribbon for quick access.
• Discover the power of smart filtering using fields like Inspection Method and Inspector to zero in on events and schedules that matter most to your program.
• Update data efficiently with new mass update fields for Events & Schedules

PCMS Mobile Track

PCMS Mobile – Smarter Field Execution Starts Here

Optimize inspections. Reduce rework. Deliver results.

We’re excited to showcase the latest advancements in PCMS Mobile®, our proprietary cloud-based field inspection platform—purpose-built to eliminate paper, improve data accuracy, and streamline execution across the mechanical integrity lifecycle. Far more than just a mobile version of PCMS, this solution delivers real-time data capture, integrated quality control, and seamless reporting—all designed to reduce rework and boost operational efficiency.

In this breakout session, we’ll highlight what’s new in the latest Q1 2025 release, including expanded UT datalogger support, and the new Web Portal for smarter work assignment and pre-upload data review.

The session will include a live demo, success stories from the field, and an open Q&A to share best practices and gather feedback. Whether you're evaluating Mobile or scaling it across multiple sites, you’ll walk away with real-world strategies to optimize your inspection program.

Legacy Challenges: Paper-Based Workflows & Delayed Data Access

Before PCMS Mobile, inspection teams faced persistent inefficiencies that limited performance:

• Inconsistent reporting
• Rework from late-stage data validation
• Administrative burdens on planners, coordinators, and QC reviewers
• Slow turnaround for actionable insights

What’s New in PCMS Mobile

In the Q1 2025 release, we’ve taken PCMS Mobile to the next level with:

• A new Web Portal for smarter work assignment and optional preliminary QC review before syncing to PCMS
• Expanded UT datalogger compatibility, improving hardware support and field flexibility
• Enhanced offline functionality and faster, automated report generation
• Seamless integration across the PCMS ➝ Mobile ➝ OneSuite workflow
• Real-world tips and takeaways from sites already achieving measurable efficiency gains

What You’ll Explore

• How customers are reducing inspection cycle time by up to 40%
• How real-time data validation reduces rework and enhances inspection quality
• Best practices for planning, executing, and reviewing inspection data in the field
• Success stories and lessons learned from real-world users

Asset Integrity Engineering Track

Top 5 Mechanical Integrity Audit Observations

As integrity professionals, we play a role in facilitating a program that not only meets the minimum regulatory requirements per OSHA PSM 1910.119(j) and EPA RMP 40 CFR 68.73, but a program that is best in class. Every 3 years, owner-operators are required to conduct an audit of mechanical integrity as part of the PSM internal audit.

Our experience in these audits show that, even among programs of different maturity levels and different industries, there are common patterns and themes around the program level deficiencies and improvement areas.

This session will explore the industry trends around regulatory audit findings and the ‘low-hanging fruit’ actions that you can take back to your facility for immediate MI program enhancements.

Asset Integrity Engineering Track

Lessons Learned from Mechanical Integrity Incidents

Mechanical integrity often play a key factor in industry events – ranging from missed inspections and inadequate monitoring techniques to factors that were unanticipated based on industry knowledge.

In this session, we will review relevant industry incidents that have key factors identified in the mechanical integrity element. We will explore how our day-to-day work could potentially impact proper asset management and safety down the road.

Asset Integrity Engineering Track

Mechanical Integrity Through the Lens of Process Safety Management (PSM)

Mechanical Integrity (MI) is one of the fourteen elements of Process Safety Management (PSM). In the industries – we often find the MI team or department operates in a silo, but there is a reason why this has become the norm. MI element is, by far, the most technically extensive topic of the PSM elements, which require numerous different areas of expertise.

How does MI fit together with all the other elements within PSM? And what processes are implemented at your facility so that MI team or department do not lose sight of the PSM goals?

In this session, we will explore the connection of MI to other PSM elements and the criticality of its awareness.

Asset Integrity Engineering Track

Progressing Your IOW Program

Integrity Operating Windows (IOWs) continue to gain industry attention as they enhance MI and RBI programs by contributing to real time notification of increased risk of equipment damage between scheduled inspections. The IOW development process requires a good understanding of the unit operations, process conditions, and their effect on materials degradation. IOW implementation requires ensuring the necessary instrumentation and sampling points are available and developing a framework for notifying personnel of breaches in IOW limits as well as identifying roles, responsibilities, and response times. Mechanical Integrity software connected to a data historian, lab database, field data, etc. is useful in communicating IOW breaches and managing IOW data.

This session will include a discussion of the current API 584 guidelines as well as what’s next with API 584 and cover the following:

• Insights into the IOW development process
• Best practices in IOW implementation
• IOW management and benefits of the PCMS Process Monitoring Module

Funding for Software, RBI, and Standardization Projects

Best practices for managing a Mechanical Integrity (MI) program like using PCMS, PCMS Mobile, and implementing DMRs, IOWs, and RBI are well understood to improve process safety. However, the financial value case necessary for funding approvals can be less clear. In this session, Lisa will share her experiences about what has worked (and not worked) over a career with successful funding of five large-scale projects across five different operating companies.

Join us in this session to learn more about:

• Typical value cases for MI improvement initiatives
• Building a business case for your ideas
• Sources of funding
• Logistics of implementing site-wide or corporate-wide improvement projects