Process safety • Hazard studies • Risk reduction
Process Safety
Practical process safety support for organisations handling hazardous substances, energetic processes, flammable gases, vapours, combustible dusts and complex industrial operations.
We help companies establish and strengthen Process Safety Management systems, understand major accident hazards and maintain effective risk controls throughout the lifecycle of hazardous operations.
Process Safety as a Discipline and Management System
Process safety is the organisational and engineering discipline used to prevent major incidents involving hazardous materials, loss of containment, fire, explosion, toxic release and uncontrolled energy. It is broader than a single study and distinct from general occupational safety.
An effective Process Safety Management system brings together leadership, technical knowledge, competent people, reliable safeguards, operating discipline and lifecycle assurance. These elements operate continuously and reinforce one another; they are not a linear sequence of project steps.
ExConform supports organisations in strengthening these interconnected elements, from governance and hazard analysis through to engineering controls, management of change, assurance and learning from operational experience.
Corrosive and highly toxic substances
Process Safety for Hazardous Chemical Operations
Processes involving corrosive or highly toxic substances require careful control of containment, compatibility, transfer, ventilation, exposure pathways and emergency response. A relatively small loss of containment can create serious consequences for operators, adjacent work areas, the environment and the wider site.
We support the review of chemical storage, dosing, treatment, transfer and process systems to identify credible failure scenarios and define practical prevention, detection, mitigation and recovery measures.
Delivered by Senior Process Safety Expertise
The service is delivered by a highly skilled professional with years of experience as a Process Safety Subject Matter Expert for a global aerospace industry organisation and as a consultant across multiple industrial sectors in Europe.
This combination of corporate process safety ownership and cross-sector consulting experience enables practical, risk-based and defensible support for complex hazardous operations.
Process Safety Services We Offer
We support organisations with structured process safety services from management system development through to detailed hazard studies and technical risk assessments.
Establishing Process Safety Management Systems
We help organisations define and implement practical Process Safety Management structures, responsibilities, procedures and documentation suitable for their hazardous operations.
Facilitating HAZOPs for Hazardous Processes
We facilitate structured HAZOP studies to identify process deviations, causes, consequences, existing safeguards and recommended actions.
Facilitating LOPA and SIL Identification Studies
We support Layer of Protection Analysis and SIL identification studies to determine whether safeguards are adequate and whether safety instrumented functions are required.
Dispersion Modelling for Hazardous Releases
We support consequence assessment for incidents involving hazardous gases and vapours, helping organisations understand potential release behaviour and impact zones.
Explosion Protection Documents
We prepare or support Explosion Protection Documents, including structured assessment of explosion hazards, ignition source controls and required protective measures.
ATEX / DSEAR and Hazardous Area Classification
We support explosion safety assessment, identification of potential ignition sources and classification of hazardous areas for flammable gases, vapours, mists and combustible dusts.
On-site and off-site impact
Process Hazard Analysis and Environmental Risk Assessment
Process Hazard Analysis methods such as HAZOP and LOPA help identify credible hazardous events, understand their causes and test whether safeguards provide sufficient risk reduction. Where a scenario may extend beyond the immediate process area, consequence and environmental assessment can be used to evaluate a wider impact footprint.
Environmental Risk Assessment (ERA) can consider release pathways, sensitive receptors and consequences both within the site boundary and in surrounding off-site areas. This supports proportionate prevention, mitigation, emergency planning and communication decisions.
Typical Process Safety Deliverables
Select the right analysis method
Different Types of Process Hazard Analysis
HAZOP, LOPA and Bow-Tie assessments answer different questions. They can be used independently or combined to move from structured hazard identification to risk evaluation, barrier assurance and clear communication of major accident scenarios.
Hazard and Operability Study
A systematic, multidisciplinary review that applies guidewords to process parameters and operating intentions. HAZOP identifies deviations, causes, consequences, existing safeguards and actions for further risk reduction.
Explore HAZOP servicesLayer of Protection Analysis
A semi-quantitative method used to test whether independent protection layers provide sufficient risk reduction for a defined scenario and to support decisions on additional safeguards or SIL targets.
Explore LOPA servicesBarrier-Based Scenario Assessment
Bow-Tie analysis presents the relationship between threats, a central loss-of-control event, consequences and the preventive and mitigative barriers intended to manage the scenario. It is especially useful for barrier ownership, assurance and communicating complex risk pathways to operational teams.
Supporting Technical Studies
Process Hazard Analysis is often strengthened by consequence, environmental, explosion and functional safety studies. We help select the right level of analysis and translate the findings into practical risk reduction actions.
SIL Identification
Identification of safety instrumented functions and required SIL targets based on process risk scenarios.
Dispersion Modelling
Consequence modelling for hazardous gas and vapour releases to support impact assessment and emergency planning.
Environmental Risk Assessment
Assessment of release pathways, environmental receptors and potential on-site and off-site consequences.
Ignition Source Analysis
Systematic assessment of effective ignition sources, control measures and ATEX-related design considerations.
Hazardous Area Classification
Classification of zones where explosive atmospheres may occur, supporting equipment selection and risk control.
Explosion Protection Review
Structured review of explosion prevention, protection, mitigation and associated technical documentation.
Typical Applications and Sectors
Process safety principles apply wherever hazardous substances, flammable materials, pressurised systems, reactive processes or energetic events may create major accident potential.
Hazardous gas systems
Hydrogen, fuel gases, toxic gases, process gases, vapour releases and gas handling equipment.
Corrosive and toxic chemicals
Bulk storage, day tanks, dosing systems, treatment baths, pipework, transfer points and chemical process interfaces.
Flammable liquids and vapours
Storage, transfer, mixing, heating, cleaning, ventilation and release scenarios involving flammable atmospheres.
Combustible dusts
Powder handling, plastic granulate conveying, dust collection, filtration and dust explosion risk areas.
Industrial process equipment
Reactors, vessels, compressors, blowers, pumps, pipework, control systems and utility systems.
Aerospace and advanced manufacturing
High-reliability operations, complex processes, hazardous materials and strong management system expectations.
Environmental and site risk
Process releases with potential impacts on drainage, surface water, soil, air pathways and off-site receptors.
Multi-sector industrial operations
Manufacturing, chemical handling, energy systems, test facilities, laboratories and pilot plants.
Major accident hazard scenarios
Loss of containment, toxic release, fire, explosion, runaway conditions and escalation between process areas.
Why Process Safety Matters
Process safety incidents are often the result of multiple small weaknesses aligning: incomplete hazard identification, weak safeguards, unclear responsibilities, insufficient operating discipline, poor change control or inadequate emergency planning.
A strong process safety approach helps organisations move from reactive compliance to proactive risk management, ensuring that credible major accident scenarios are understood, controlled and documented.
Need Process Safety Support?
Whether you need a Process Safety Management framework, HAZOP facilitation, LOPA and SIL identification, hazardous chemical process review, environmental risk assessment, dispersion modelling, ATEX / DSEAR assessment, hazardous area classification or explosion protection documentation, we can support you with practical, technically grounded process safety expertise.