Petrochemical & Chemical safety solutions

Petrochemical & chemical

Gexcon has years of experience in understanding and analysing the risks associated with the use of hazardous materials in the petrochemical and chemical industry. We have experts in accidental releases, fires and explosions, who have the expertise in utilising advanced risk assessment and consequence modelling tools. Because of this, we can continually provide significant value to risk and hazard assessments.

As leading consultants in process safety and risk management, we aim to increase awareness and understanding of process safety at our clients’ facilities and help them mitigate the risks of potential accidents. We also strive to provide practical recommendations to achieve feasible solutions to manage process risk and ensure compliance with the relevant regulations.

We have experience in performing safety assessments for various petrochemical and chemical facilities/ processes, including but not limited to:

  • Fertiliser (e.g. ammonium nitrate through the Haber-Bosch process)
  • Organic pigments
  • Dyes and inks
  • Aromatics
  • Synthesis gases
  • Hydrocarbons
  • Alcohols and solvents

 

 

 

 

Contact us for more information on our Petrochemical & Chemical safety solutions

 

Contact us

 

 

 

Learn more about safety and risk management in the Petrochemical & chemical sector

blog
How to model toxic dispersions in EFFECTS

How to model toxic dispersions in EFFECTS

Find out how to model the consequences of atmospheric dispersion for an accidental toxic release with EFFECTS consequence modelling software.

Case Study
Investigation findings and lessons learned in the West Fertilizer explosion

Investigation findings and lessons learned in the West Fertilizer explosion

This paper presents the results of our investigation into the cause and origin of the West Fertilizer explosion.

blog
Why chemical properties are important

Why chemical properties are important

The physical state of the chemical and its typical properties are extremely important when evaluating a loss of containment scenario.

blog
How to do a Quantitative Risk Assessment (QRA)

How to do a Quantitative Risk Assessment (QRA)

This article discusses the main steps required to perform a QRA to evaluate all potential loss of containment scenarios involving the release of dangerous chemical substances in process, chemical and petrochemical facilities.

blog
Societal Risk maps as a clear geographical representation of risk

Societal Risk maps as a clear geographical representation of risk

This blog provides some background about these geographic presentations of Societal Risk and explain how to interpret their results when using Gexcon’s risk modelling software RISKCURVES.

blog
How to simulate plumes of large fires in EFFECTS

How to simulate plumes of large fires in EFFECTS

Both pool and warehouse fires can result in highly toxic fumes. The assessment of the toxic concentration levels of these combustion products transported along the plume trajectory is of utmost importance. Safety professionals can use this information for hazard identification, safety analysis and emergency planning.

blog
Fire and explosion hazards: What to expect if there is a leak

Fire and explosion hazards: What to expect if there is a leak

This article will explain the importance of assessing the consequences of a potential release of a hazardous chemical substance and introduce you to the different dangerous phenomena that can occur upon such a loss of containment scenario.

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Ammonia Risk Assessments - How advanced consequence modelling can improve safety management

Ammonia Risk Assessments – How advanced consequence modelling can improve safety management

Advanced consequence modelling can improve ventilation/dilution levels and detection times from common leaks during ammonia risk assessments.

blog
High Flash Point Liquids – does the approach for hazardous area classifications need to change?

High Flash Point Liquids – does the approach for hazardous area classifications need to change?

The Energy Institute Model code of safe practice Part 15 provides an approach to assess high flash point liquids for Hazardous Area Classifications.

However, recent studies indicate that the approach may be over-conservative in some instances, resulting in potentially unnecessarily high costs.

blog
Introduction to HAZID (Hazard Identification)

Introduction to HAZID (Hazard Identification)

The high-level nature of a HAZID is suitable to review the design at an early stage without requiring in-depth knowledge of the operation.

blog
Introduction to ATEX Directives

Introduction to ATEX Directives

ATEX is a set of two European Union Directives that have been established to protect employees from explosion risks within industries.

blog
Passive Fire Protection (PFP): a brief guide

Passive Fire Protection (PFP): a brief guide

PFP is a vital construction element installed in a building or on process equipment that prevents or slows down the spread of fire

blog
How to prevent and mitigate against ammonium nitrate explosions?

How to prevent and mitigate against ammonium nitrate explosions?

The risk of ammonium nitrate detonations can be reduced by the implementation of several measures regarding the storage of the chemical.

blog
How can ammonium nitrate explode?

How can ammonium nitrate explode?

The AN’s decomposition reactions are all exothermic thus they all contribute to heat generation, further melting the solid ammonium nitrate, and presenting possible runaway conditions.

blog
How dangerous is ammonium nitrate?

How dangerous is ammonium nitrate?

Ammonium nitrate is used worldwide as fertilizers. Even though it is non-combustible in most conditions, it can have a devastating effect.

Case Study
DSEAR Compliance Analysis - Hand Sanitiser Manufacturing

DSEAR Compliance Analysis – Hand Sanitiser Manufacturing

DSEAR Compliance for the handling of flammable liquids.

Prove the basis of safety needed to produce hand sanitiser that contains a significant proportion of (highly flammable) alcohol that will show compliance with DSEAR.

blog
How to simulate ammonia releases

How to simulate ammonia releases

Releases of ammonia can have potentially harmful effects on workers and the public. If ammonia is under pressure, the risk of exposure increases since larger quantities of the refrigerant has the potential for rapid release into the air.

blog
CO2 hazard assessment

CO2 hazard assessment

Shell FRED is an appropriate tool for CO2 hazard assessment in many cases, particularly due to the speed at which calculations can be set up and run.

blog
Beirut port explosion: What we know from previous explosions caused by ammonium nitrate

Beirut port explosion: What we know from previous explosions caused by ammonium nitrate

The Beirut port explosion was caused by 2,750 tonnes of ammonium nitrate stored unsafely in a warehouse.

Course
Explosion Science

  Explosion Science

Gexcon has developed a unique training course for obtaining a full understanding of the phenomenon of explosions, including consequences, prevention techniques and current regulatory requirements for a safe and compliant working environment. The course covers gas and dust explosion theory, DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) and ATEX regulations, ignition theory, hazardous area classification, risk assessment and protection concepts….

Course
Gas Explosion Hazards Course

  Gas Explosion Hazards Course

Gas explosions are unfortunately still common in the process industry and can lead to injuries, fatalities, property damage, business interruption and environmental pollution. In fact, gas explosions are the biggest contributor to losses in the hydrocarbon industry. It is therefore of paramount importance to reduce the risks when handling flammable gases and vapours.   This course is looking into gas…

Course
Hazardous Area Classification

  Hazardous Area Classification

Hazardous area classification is an important first step towards reducing the likelihood of ignition of clouds of flammable gas, vapour, and/ or dust. Mechanical and electrical equipment used inside a classified area shall be approved for use in that area. The classification concerns areas both inside and outside process equipment and is closely related to release and dispersion phenomena. Ventilation…

Course
Self-Declaration of Mechanical Equipment to be Used in Flammable Atmospheres

  Self-Declaration of Mechanical Equipment to be Used in Flammable Atmospheres

The ATEX Directive 2014/34/EU demands that electrical and mechanical equipment to be used in potentially explosive areas is approved for that purpose. This approval can be performed by the manufacturers themselves if the equipment is to be used in zone 2 and 22 for electrical and mechanical equipment, and in zone 1 and 2 and 21 and 22 considering mechanical

Course
Dust Explosion Hazards Course

  Dust Explosion Hazards Course

Dust explosions still occur on a regular basis in the process industry causing injuries, fatalities, property damage, business interruption, and environmental pollution. This is in spite of the wealth and knowledge available to prevent the accident and to reduce the consequences to a minimum.   In this two-day advanced course on dust and powder explosion hazards, you will learn all…

Course
Process Safety Management

  Process Safety Management

In this training course, participants will learn the fundamentals of Process Safety Management, and the main standard frameworks for it.

Case Study
Toxic and flammable gas cloud detectors layout optimization using CFD

Toxic and flammable gas cloud detectors layout optimization using CFD

The quantity and positioning of hydrocarbon and toxic gas detectors is a crucial factor for the effectiveness of the detection process.

The total number and placement of detectors should be optimized for maximum effectiveness.

Course
EFFECTS Course (Online)

  EFFECTS Course (Online)

This course is aimed at introducing the principles of consequence modelling and EFFECTS user interface and giving an overview of all the models available within the software, which will be conducted online.

Course
FLACS I Course (Online)

  FLACS I Course (Online)

This course is the online version of FLACS I Course. It covers the standard modules in FLACS, such as geometry import and generation, gas dispersion, explosion, and fire, as well as liquid pool spread. It also comprises presentations on validations, explosion mitigation, QA, and probabilistic risk analysis. This course combines theory, demonstrations, and practical exercises with FLACS software. Therefore, students…

Our services that support the Petrochemical & chemical sector

Incident investigation and litigation support

Incident investigation and litigation support

Gexcon can help with all aspects of incident investigations, from coordinating the investigation to conducting root cause analysis, providing recommendations, implementing strategies to prevent further incidents from occurring, and acting as expert witnesses in ongoing investigations.

Process Hazard Analysis (PHA)

Process Hazard Analysis (PHA)

Most industries work with potentially hazardous materials, either they are in the form of gases, liquids, or dust. Knowing how these materials are potentially harmful, it is an obligation for companies working with such materials to identify and evaluate the dangers involved.

Process safety and risk management

Process safety and risk management

Process safety and risk management in process facilities involve the systematic identification, assessment, and mitigation of risks associated with the operation of industrial processes.

Regulatory Compliance

Regulatory Compliance

While the primary focus of any process safety plan should be to drive the risk to a level which is As Low As Reasonably Practicable (ALARP) to protect people, the environment and business, there are several regulatory requirements that must also be met to drive continual improvement. Organisations across the globe and from all industries are adopting the use of…

Consequence and risk modelling studies

Consequence and risk modelling studies

Companies handling flammable and/or toxic materials are exposed to hazards during storage, transporting, and processing. As such, it is crucial to understand the consequences of a potential loss of containment of a hazardous event when performing a risk assessment.

Testing of Passive Fire Protection

Testing of Passive Fire Protection

The manufacturers of PFP products need to ensure their products fulfil the required fire-resistant performance. Therefore, PFP products need to be verified through fire testing and certified by a third-party inspector.

Gas, Vapour and Liquid Explosion Properties Testing

Gas, Vapour and Liquid Explosion Properties Testing

The handling of gases, liquids and selected substances may constitute risks for explosions. Knowing the properties related to the risk of these materials, such as the ignition and explosion characteristics, is therefore essential.  By being aware of the properties of materials handled in your plant or used in your products, it allows the necessary safety precautions to be taken to…

Explosion Mitigation System Testing

Explosion Mitigation System Testing

Equipment and protective systems to be used in potentially explosive atmospheres must fulfill the essential health and safety requirements as described in the ATEX Directive 2014/34/EU.

Ignition Hazard Assessment for mechanical equipment and protective systems

Ignition Hazard Assessment for mechanical equipment and protective systems

Equipment and protective systems used in explosive atmospheres shall be assessed according to their ability to prevent them from becoming ignition sources and their ability to protect against the consequence of an explosion.

Dust explosion properties testing

Dust explosion properties testing

A very important basis for managing the risk of combustible dusts is to understand their ignition and explosion properties by testing them so that you can avoid situations and conditions that could make those dusts explode.

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