Process Safety & Risk Management

Facilities, where complex industrial processes or hazardous materials such as flammable dust, gases, or liquids are involved, are always associated with hazards.  To make a valid assessment of the risks, both from an operational and financial perspective, years of experience is needed. By working together with you, our consultants will evaluate the hazards and risks of your facility entirely and systematically, so that the level of risk will be identified based on the level of severity. 

With over 40 years of experience in the field of safety and risk management, Gexcon can assist with identifying your hazards, understand your risk and contribute to your overall safety performance by implementing safety measures and providing advice on risk reduction.


Quantitative & Qualitative Risk Analysis and Assessments

Risk Analysis plays a vital part of safety management for projects where inherent risks are associated.  In order to eliminate or reduce (as far as reasonably practicable) the risks in your workplace, a risk assessment must to be carried out.

Qualitative and quantitative techniques are important risk analysis tools and help develop a comprehensive risk management plan.

Using our expertise within the field of process safety and risk management, Gexcon has a proven track record in developing bespoke or standardised qualitative risk assessments in line with relevant guidelines or company requirements for facilities across a wide range of industries, including food, pharmaceutical, automotive, energy and chemical.

This includes qualitative or semi-quantitative processes such as HAZID, HAZOP and LOPA.

Please click on the link below for an overview of the related services.

Layer of Protection Analysis (LOPA) & IEC61508/61511 Safety Instrumented Systems (SIS) Verification

Safety Instrumented Systems (SIS) are defined by BS EN 61511-1, and this standard requires that Functional Safety Assessments (FSAs) are carried out to determine whether the protective layers in place are sufficient to reduce the risk of major accident to a tolerable level.

BS EN 61511-1 defines a lifecycle approach to the specification and management of Safety Instrumented Systems. Stage one of this lifecycle is often known as FSA-01 and consists of 3 key activities:

  1. Hazard and risk analysis of the design.
  2. Allocation of safety functions to protective layers.
  3. Design specification of protective systems.

A Layer of Protection Analysis (LOPA), alongside hazard analysis techniques such as HAZID and HAZOP, is an accepted simplified semi-quantified risk assessment technique to meet the requirements of FSA-01.

Gexcon is able to carry out HAZID, HAZOP and LOPA studies to provide independent FSA-01 assessments that meet the requirements of Stage 1 of the BS EN 61511-1 lifecycle approach.

Part of the BS EN 61511-1 lifecycle also includes a requirement for an independent verification of the various stages of the lifecycle. Gexcon is also able to provide independent verification of FSA-01 assessments.

Hazardous Area Classification (HAC)

Hazardous area classification (HAC) is a requirement of DSEAR (Dangerous Substances and Explosive Atmosphere Regulations 2002) and ATEX Directive which identifies when an explosive atmosphere exists in such an extent that it requires specific measures to protect personnel against the dangers of explosions and results in the need for area classification or zones.

Not only does it look at materials associated with fire or explosion hazards such as flammable or explosive gases, vapours, mists or dusts but also at the installation of electrical equipment which must be purposefully designed with hazardous area zone classification in mind to reduce the potential of an ignition source.

Gexcon has significant experience across a wide range of industries in carrying out hazardous area classification, or simply peer review a previously conducted classification. Our experienced engineers can provide in-depth advice on risk reduction measures to ensure your facility remains legally compliant and reduce risks associated with capital and operational expense implications.

Fire Risk Assessments (FRA)

Employers have a responsibility for ensuring their premises have an up-to-date Fire Risk Assessment (FRA) to facilitate the safety of their employees and minimize the risks associated with fires and explosions.

A Fire Risk Assessment (FRA) is a systematic process which identifies hazards and risks associated with fires within your facility,  determines the likelihood of a fire occurring and the consequences if a fire were to occur.

Gexcon has significant experience within the field of fire safety, our experienced engineers can assist with the identification and evaluation of such risks and provide guidance on risk reduction measures.

Facility Siting (FSS)

A Facility Siting Study (FSS) is a requirement under OSHA’s (Occupational Health & Safety Administration) Process Safety Management (PSM) Regulation which requires re-validation every five years under OSHA standard 1910.119.

The core purpose of a facility siting study (FSS) is to evaluate the potential damage that a workplace explosion, fire or toxic chemical incident could cause to occupied buildings in the work area and ensure that the risk faced by workers inside the building is not disproportionate to those who are working outside.

Facility siting is a continuous process which can be implemented during the design stage of a facility through to the operations stage to identify potential and current risks.  Employers have the responsibility, when such risks are identified, to implement hazard controls and alter work processes to reduce risk levels.

Gexcon has significant experience within the field of risk management, our experienced engineers can assist with the identification and evaluation of such risks and provide guidance on risk reduction measures.

Pre-Start-Up Safety Reviews (PSSR)

Pre-Start-Up-Safety Review (PSSR) forms part of the planning process and consists of a thorough safety inspection to a new or modified facility. The overall goal is to ensure that the facility meets the criteria and original design or operating intent and promotes a safe working environment prior to commissioning.

Potential hazards due to the introduction of new hazardous materials, changes to installations or procedures for example, may have a detrimental impact on the operational ability of a facility.  By conducting a PSSR it presents the opportunity to review all safety measures and ensure emergency procedures are suitable and sufficient should an incident occur.

Gexcon has significant experience within the field of risk management, our experienced engineers can assist with the identification and evaluation of such risks and provide guidance on risk reduction measures.

The cost of our consulting service depends on many factors, such as the scope of studies. Please let us know your preference by sending us a request for a quotation by filling out the available enquiry form.

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