Process Safety

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Safety = #1

Something to be prevented at all-time producing chemicals or pharmaceuticals are incidents and accidents that give an unintended release of materials and energy leading to damaged installations, spills, or even worse: injuries and fatalities.

We can think of numerous reasons why incidents could happen, such as poor process understanding, insufficient operator training, technical defects, human errors, poor understanding of the chemistry (including side reactions), to name a few.

No matter what the cause is, we believe that incidents and accidents can be reduced to an acceptable risk at all times. How we do this? By using proven methodologies that work combined with a structured approach.

What we Do

Three things.

  1. The development of Process/Technical Safety Management Systems
  2. The assessment and improvement of your current Process/Technical Safety Management Systems against industry best practices and legal requirements (yes! We have practical experience too) 
  3. Support sustainability initiatives to improve unit performance. 

How we work:

1. It starts with you.

Employee involvement is key and requires a competent and experienced team of individuals, so we ensure that this is done. Ideally, each team should include at least one professional who specializes in the specific process being used. Where to find this professional? Give us a call. 

2. Proper understanding, having all the right information available.

Before we can start with the identification of your risks, it is to be known what you are dealing with from an equipment, materials, and process perspective. Any information missing? No worries. We are there to help. That is what the process safety engineering specialists at Chemploy do. 

We require good process safety information to make great assessments. But we also can help you improve some of your process safety information from SDS, P&IDs, Operating Envelopes, and Safeguarding narratives. We work to the relevant design codes in your industry from the PGS guidelines, API, ANSI overarching by requirements set out in ASME and ISO and BRZO requirements. 

We follow the practices from Seveso III  (link below) 

So, when all required information is in place, we can start analyzing the hazards and come to phase 3

3. Process Hazard Analysis

We have an extensive toolbox at your disposal performing risk assessments based on many methodologies. What methodology fits best? We are looking forward to discussing this with you. 

Our aim is to assess and maintain the basis of Process Safety in your plants through cyclic risk reviews. We may also offer services in a host of support assessment listed below as part of your legal studies. 

To give an idea of what we can do; in the past, our employees have successfully worked with methodologies starting with a ‘what if’ analysis up to more sophisticated methodologies such as: 

  • Hazard Identification (HAZID), Hazard and Operability Studies (HAZOP)
  • SAFOP/ electrical HAZOP
  • LOPA Analysis (using PHA Works and PHA Pro)
  • Quantitative Risk Assessment (QRA), Fire Risk Assessment (FRA), 
  • Systems Assurance, Hazard Analysis HAZAN, Hazard Management and Closure
  • Human Factors Assessment 
  • FMEA
  • Assessment of Safety Integrity Levels (SIL)
  • FMEA/ FMECA, 

Once the risks are known, we support the full implementation to mitigate these risks.

4. Operating procedures

Sound operating procedures are key for safe operations. We assist in reviewing and improving Standard Operating Procedures (SOPs) and streamline them to address the consequences of deviations in key operating steps. 

5. Training & Education

We can train your operators and engineers to conduct risk assessments and are able to provide a gap analysis to identify your staff’s training needs.

6. Pre-start-up safety reviews

Check, check, and double-check. Whether it is a new or modified installation, a safety review is always required before production starts. We help build robust start-up documentation for commissioning and field punch activities

7. Integrity

We want to ensure that the mechanical integrity of your components always meets the requirements. Together with respected partners, we can organize inspections for process units and equipment, including pressure vessels, piping systems, relief and vent systems, emergency shutdown systems, control systems. The proper documentation of inspections? We ensure that too!

In addition, we can support your integrity program by conducting Fault Tree and Event Tree Analysis and reliability block diagrams.

8. MOC

We all understand how important it is to improve plants. Like all engineering processes, this comes with benefits and tradeoffs. We help you to develop a robust MOC system for your engineering units and organizational changes that may impact adverse health, safety, and environmental threats.

9. Incident Investigation

An essential part of proper safety management is that an investigation procedure is in place on incidents that result in (or could have resulted in) disaster. We offer services investigating process safety incidents, production losses, and near-miss data to uncover underlying root causes that may be both a production threat and a threat to the Health and Safety of your workers.

We make use of Tripod Beta, Taproot, RCAT, and a host of techniques to find the immediate and underlying root causes and propose the means to reduce repeat failure and help you on your journey to reliable and profitable operations.

Did an incident occur? You may be aware that an external professional often sees more and dares to pinpoint and put the finger on the sore spot. We are not afraid of losing our job. We are afraid that it will happen again and are there to ensure that it will not happen again.

10. Compliance Audits

You should recertify all credentials to keep up to date with evolving practices and technology. 

We are able to perform gap assessments against industry standards as part of your Tier 2 Audit programs. Need assistance? Contact us.

More information? Contact us or have a look at:

  1. https://osha.europa.eu
  2. https://www.iso.org/iso-45001-occupational-health-and-safety.html 
  3. https://www.aiche.org/ccps/resources/psid-process-safety-incident-database
  4. https://www.csb.gov/investigations/
  5. https://eur-lex.europa.eu/legal-content/EN/TXT/?uri=CELEX:32012L0018