Process Safety/Risk Management Services
We offer the most efficiently run PHA meetings that most of our clients have ever experienced, often cutting meeting time down by as much as 50%. We do this by performing tasks outside of the PHA meeting that don't need input from the PHA team. This allows PROCESS, with our unique knowledge base, to quickly, efficiently, and thoroughly move through the PHA in less time than most trained facilitators are capable of doing. This translates to less time that you and your personnel have to sit through PHA meetings....and let's face it, time is money. Our experience as plant operations chemical engineers and process designers also gives us exceptional insight on most aspects of a processing facility. Give PROCESS a try and you too can benefit from the most efficiently run PHA meeting you have ever experienced.
Experience is critical in achieving optimal results within a PSM/RMP program. Our engineers have performed over 500 PHAs on nearly 400 different processes for over 60 different facilities throughout the U.S. and Puerto Rico, as well as clients in Argentina, Canada, Taiwan, Pakistan, and Russia. We have also performed dozens of compliance audits, including NEP assessments, and dozens of SIL Selection Analyses, some including Layer of Protection Analyses (LOPAs). We have performed process safety work in Refining, Petrochemicals, Chemicals, Pulp & Paper, and the Nuclear industry. View a Detailed List of Process Safety Experience or view a breakdown by Types of Process Safety Services.
View Project Summaries of a few typical Process Safety/Risk Management projects completed by PROCESS.
PROCESS has a wide range of experience using many of the commercially available software packages for documenting process hazard analyses (PHAs). We also have experience using in-house database programs developed by our customers at the plant or corporate level. This experience means we can quickly and easily apply our knowledge regardless of the software your facility uses.
View Resume for Mel Coker, Director of Process Safety/Risk Management Services.
PROCESS' process safety and risk management services help our clients meet their safety, health, and environmental compliance needs in a thorough, systematic, and efficient manner. We have the experience to address issues ranging from operational risk, equipment integrity, loading limits or naturally occurring hazards.
Our services include:
- PSM programs
- Process Hazard Analyses (PHAs)
- Layer of Protection Analyses (LOPAs)
- Resolving/Engineering/Implementing PHA recommendations
- PHA Revalidations
- Safety Integrity Level (SIL) selection analyses for Safety Instrumented Systems (SISs)
- Layer of Protection Analysis (LOPA)
- PSM Compliance Audits
- Preliminary Hazard and Operability Studies (HAZOPs)
- New Plant HAZOPs and PHAs
- PHA facilitation training
- Incident investigation training
- Independent Program Assessments
- Evaluating extent of regulatory coverage and documenting legal justification for coverage boundaries
- Performing hazard assessments
- EPA Risk Management Plans
- Plan Development
- RMP Strategic Planning
- Compliance Audits
- Offsite Consequence Analysis
- Hazards Assessment
- Emergency Response Programs
- Worst Case Scenario and ARS Documentation
- EPA Risk Management Plan Updates
- Mechanical Integrity Program Development
- Mechanical Integrity Audits
- Decommissioning Studies
- EPC process support
- Facility Siting Analysis and Evaluation
- Pre-Acquisition Due Diligence Surveys
- Operating Procedures Development
- Review or Revalidation of Operating Procedures
- Operator Task Analysis
- Incident Investigation
- Technical Writing
- Assistance in abating OSHA citations
- Litigation support and Expert Witness services
- Developing Process Safety Information, including
- Process flow diagrams (PFDs)
- Process chemistry
- Chemical compatibility matrix
- Maximum Intended Inventories
- Safe upper and lower operating limits and consequences of deviations
- Materials of construction
- Piping and instrumentation diagrams (P&IDs)
- Electrical Classification drawings and interpretation of codes and standards regarding area electrical classification
- Relief System design and design basis, including determining relief valve sizing bases and evaluating flare header capacity, liquid knockout requirements, and flare stack design for adequacy
- Ventilation System design information such as compressor building ventilation systems, including interpretation of applicable codes and standards for determining ventilation requirements
- Identifying design codes and standards employed in the design of a process
- Material and energy balances
- Safety systems documentation, including safety system plot plans and written descriptions of safety systems (e.g., interlocks, detection, suppression, utility, and containment systems)
- Identifying recognized and generally accepted good engineering practices (RAGAGEP) used in the design of a process.
Process Safety Related Training Courses
PROCESS currently offers several process safety related training courses. The shorter classes are offered via Webinar while the more in depth classes are offered on-site at client's facilities. Read more about the Training Classes Offered
OSHA Refinery NEP Directive Support
Don't get caught by surprise. Help ensure compliance before OSHA performs a National Emphasis Program (NEP) audit at your refinery.
As part of the new OSHA NEP Directive (CPL 03-00-004 - Petroleum Refinery Process Safety Management National Emphasis Program) refineries throughout the country will be audited for compliance by OSHA inspectors. PROCESS can perform an NEP assessment for your refinery to help ensure compliance with the OSHA PSM regulation, 29 CFR 1910.119, before the OSHA auditors show up at your site.
Read more about the NEP Directive
The following is a White Paper (.pdf format) written by two associates of PROCESS who routinely use a variety of PHA documenting software, including some that were developed 'in house' by our clients. Through this broad exposure to both purchased and home-made software tools, PROCESS has gained good insight into what functionality and features users may wish to consider when selecting a software for their plant or company. We hope this helps - enjoy!
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