Process safety and risk management in process facilities involve the systematic identification, assessment, and mitigation of risks associated with the operation of industrial processes. It focuses on preventing major incidents, such as explosions, fires, toxic releases, or equipment failures, that can lead to significant consequences for personnel, the environment, and assets.
By systematically identifying, assessing, and mitigating risks, organisations can reduce the likelihood of incidents and their potential consequences, fostering a culture of safety and continuous improvement.
With over 40 years of experience in the field of safety and risk management, Gexcon can assist with identifying your hazards, understanding your risk and contributing to your overall safety performance by implementing safety measures and providing advice on risk reduction.
Quantitative and qualitative risk analysis and assessments
Risk analysis plays a vital part in 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 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.
Layer of Protection Analysis (LOPA) and 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:
- Hazard and risk analysis of the design.
- Allocation of safety functions to protective layers.
- 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 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 used to define and categorise areas within a facility where the presence of flammable gases, vapours, liquids, or combustible dusts may create a potentially hazardous environment. The classification helps ensure that appropriate measures are implemented to prevent or mitigate the risk of ignition and subsequent incidents. It also guides the selection and installation of equipment that meets the necessary safety standards and protection methods suitable for the specific zone category.
This methodology also takes into account 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)
Fire Risk Assessment (FRA) is a systematic process that involves identifying and evaluating fire hazards, assessing the potential risks, and implementing appropriate control measures to prevent or mitigate the risk of fire incidents. The purpose of FRA is to ensure the safety of occupants, protect assets, and comply with relevant fire safety regulations and standards.
FRA enables the implementation of preventive measures to reduce the risk of fires. It guides the selection and installation of fire detection and suppression systems, proper storage and handling of flammable materials, installation of fire-resistant construction materials, and establishment of appropriate fire safety protocols. Implementing these measures can significantly decrease the likelihood of fire incidents and their potential impact.
By identifying and mitigating fire risks, organizations can minimize property damage, equipment loss, and business interruption that may result from fire incidents.
Facility siting study
A facility siting study 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.
Facility siting studies focus on enhancing the safety of the facility and its surroundings. By considering factors such as land use planning, emergency response capabilities, evacuation routes, potential hazards, and environmental protection, organisations can optimise the layout and design of the facility to maximise safety.
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. When such risks are identified, employers have the responsibility to implement hazard controls and alter work processes to reduce risk levels.
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 experts can assist with the identification and evaluation of such risks and provide guidance on risk reduction measures.
Enquiry form
Do you have any questions about our solutions? Please submit them through the form below.
