Digital Transformation of Process Safety Valve Compliance and Deficiency Management in Offshore Operations

Abstract Pressure Safety Valves (PSVs) are critical to offshore safety, yet challenges persist due to sizing complexity and evolving standards leading to frequent deficiencies. This case study presents a low-code application that integrates diverse data sources to manage PSV design issues, streamline datasheet development, and enhance compliance management. By enabling reliability monitoring and benchmarking with industry data, the solution shifts PSV management toward a proactive, risk-based approach while significantly reducing engineering man-hours. The project assessed more than 600 PSVs across multiple offshore facilities in the Gulf of Thailand. Each valve was evaluated against the latest standards to identify compliance gaps, which were then prioritized and visualized through an interactive dashboard. The workflow mapped all PSV-related processes—calculation, procurement, operation, and maintenance—highlighting inefficiencies and redundant, outdated data sources. A low-code platform was used to centralize data, streamline redundant workflows, and enhance collaboration. The approach also addressed knowledge silos by embedding safety standards into the system, reducing reliance on a small group of experienced engineers. The implementation of the new system resulted in three key improvements: (1) Centralized PSV Data Management, consolidating all PSV records onto a single platform with automated validation to ensure data accuracy and currency; (2) Compliance Dashboard, which tracks PSV non-compliance gaps over time, monitors mitigation strategies, and analyzes failure/maintenance records to benchmark against industry failure rates; and (3) Root Cause Investigation and Troubleshooting Tool, which integrates time-series data from related sensors to aid in pinpointing the causes of PSV failures, enabling more effective analysis and resolution. During early deployment across offshore assets, the solution reduced manual tracking and reporting efforts by over 70%, discovered long-standing PSV issues such as leakages and bellow failures, and enabled earlier, data-driven interventions. Real-time collaboration between offshore and onshore teams was significantly enhanced, with offshore personnel empowered to perform PSV verifications independently with minimal engineering support. Compliance with Operational Excellence (OE) standards improved significantly, and the system played a critical role in proactively mitigating high-risk scenarios. By addressing deficiencies before they escalated, the platform contributed to reducing the potential of costly incidents, which previously ranged up to millions of dollars per event. These outcomes demonstrate the system's value in improving safety, efficiency, and knowledge retention in offshore operations. This paper highlights the value of digitization effort for PSV lifecycle management in offshore operations. The solution replaces siloed systems by automating workflows, centralizing data, and delivering proactive safety insights. It improves process safety, boosts design engineering efficiency, and saves time for offshore operations and maintenance teams. The approach offers a scalable solution that enhances safety and reliability across the PSV lifecycle management.