NEXUS Event Prediction Event Prediction
Detect Process Safety Events Before They Happen
AI that continuously analyzes process data, equipment history, and near-miss records to predict PSM-relevant safety events — giving your team days or weeks of advance warning instead of incident reports.
From Reactive to Predictive Process Safety
Most process safety programs are fundamentally reactive — they respond to incidents, near-misses, and audit findings. NEXUS Event Prediction flips this model. By analyzing patterns across your DCS/SCADA historian data, maintenance records, and incident history, NEXUS Event Prediction identifies the leading indicators of process upsets and equipment failures before they manifest as safety events under OSHA PSM elements.
Precursor Pattern Detection
Machine learning models trained on refinery incident datasets identify early warning patterns in process variables — pressure excursions, temperature drift, vibration signatures — weeks before threshold violations.
DCS/SCADA Integration
Connects to existing historian systems (OSIsoft PI, Honeywell, Emerson DeltaV) without replacing your control infrastructure. NEXUS Event Prediction reads, analyzes, and alerts — it doesn’t interfere.
PSM Element Correlation
Maps predicted events to specific OSHA 1910.119 PSM elements — MI, PHA findings, MOC triggers — so your compliance team knows exactly which program element needs action before the incident clock starts.
Risk Scoring Dashboard
Real-time risk score for each monitored unit. Color-coded severity, trend lines, and projected time-to-event give operations teams clear prioritization for intervention.
Automated Near-Miss Logging
NEXUS Event Prediction auto-generates near-miss documentation when anomalies are detected and resolved, satisfying OSHA PSM incident investigation requirements with minimal manual effort.
NORMEX Integration
When NEXUS Event Prediction identifies a pattern linked to an equipment standard gap, it can trigger a NORMEX standards review — closing the loop between predictive safety and RAGAGEP compliance.
Where NEXUS Event Prediction Adds the Most Value
- Crude distillation unit — predicting overhead corrosion events before tube failures
- FCC regenerator — detecting catalyst circulation anomalies before pressure upsets
- Hydrocracker — identifying hydrogen leak precursors in high-pressure circuits
- Fired heaters — predicting tube metal temperature excursions from flame pattern data
- Rotating equipment — bearing failure prediction from vibration signature analysis
- Storage tanks — detecting seal failures from level/pressure trending patterns
The OSHA PSM Cost of Being Reactive
OSHA’s PSM standard requires facilities to investigate incidents and near-misses — but it doesn’t require you to predict them. The facilities that predict events before they happen don’t just avoid incidents: they build the documented evidence trail that demonstrates an active, functioning safety culture to OSHA inspectors.
NEXUS Event Prediction’s prediction logs, anomaly records, and intervention documentation become first-class evidence in PSM audits — showing a proactive program rather than a reactive one.
Move from reactive to predictive safety.
NEXUS Event Prediction is currently in development. If you’re a plant manager or PSM engineer at a refinery who wants advance warning — not incident reports — get in touch to discuss early access.