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Process Safety Engineering

Process safety studies are essential for identifying potential hazards and ensuring appropriate safeguards are in place.

Site Survey

Laser scanning, utility mapping, and soil investigation inform the design. We account for existing infrastructure, access constraints, and future expansion needs.

Process Modelling

Mass balance, hydraulic, and process models size equipment correctly for peak, average, and minimum flow conditions. Over-design wastes Capital expenditure; under-design fails.

3D Modelling

Revit and SolidWorks models show exactly how equipment fits in the available space. Clash detection resolves pipework conflicts before steel is cut.

HAZOP Review

Hazard and operability studies identify process safety risks, environmental releases, and equipment failure scenarios. Mitigation measures are designed in from the outset.

Peer Review

Independent chartered engineers review calculations, drawings, and specifications. Third-party verification adds confidence for boards, lenders, and insurers.

Value Engineering

Constructability reviews during design identify operational benefits and programme efficiencies. Early contractor involvement prevents expensive surprises during installation.

HAZOP Study

Hazard and Operability Analysis

HAZOP Methodology

HAZOP (Hazard and Operability Study) is a structured and systematic examination of a planned or existing process or operation. It uses guide words to identify deviations from design intent that could lead to hazards or operability problems.

NO / NOT - Complete negation of intent (no flow, no pressure)
MORE - Quantitative increase (higher flow, higher temperature)
LESS - Quantitative decrease (lower flow, lower pressure)
AS WELL AS - Qualitative modification (additional component)
PART OF - Qualitative decrease (component missing)
REVERSE - Logical opposite (reverse flow)
OTHER THAN - Complete substitution (wrong material)

Safety Assessment Methods

Comprehensive Risk Analysis

LOPA

Layer of Protection Analysis - A semi-quantitative method for evaluating the effectiveness of independent protection layers.

  • Determines required SIL level
  • Evaluates IPL effectiveness
  • Quantifies risk reduction

SIL Determination

Safety Integrity Level - Classification of safety instrumented functions based on required risk reduction.

  • SIL 1 to SIL 4 classification
  • PFD calculations
  • Architectural constraints

Risk Assessment

Qualitative and quantitative evaluation of process risks using established methodologies.

  • Risk matrices
  • Consequence analysis
  • Frequency estimation

Why Safety Studies Matter

  • Undetected hazards can lead to chemical releases, injuries, and environmental damage.
  • Inadequate safeguards fail to prevent escalation during abnormal operations.
  • Missing safety documentation creates regulatory non-compliance and insurance liabilities.
  • Poor SIL determination results in over- or under-engineered safety systems.
  • Lack of structured risk analysis increases operator uncertainty and incident rates.

Study Methodologies

HAZOP

Structured guide-word review of P&IDs to identify deviations from design intent and their consequences.

LOPA

Layer of Protection Analysis to quantify risk reduction and determine required safety integrity levels.

SIL Determination

Classification of safety instrumented functions from SIL 1 through SIL 4 based on target risk reduction.

QRA & Risk Assessment

Qualitative and quantitative evaluation of consequence severity and event frequency.

Common Water Treatment Hazards

Chemical Dosing

Acid, alkali, chlorine, and polymer handling with spill containment and neutralisation safeguards.

Confined Spaces

Tanks, vessels, and sumps with ventilation, gas monitoring, and rescue planning requirements.

Pressure Systems

Over-pressure protection, relief valve sizing, and pressure-rated equipment selection.

Electrical & Mechanical

ATEX zoning, lock-out/tag-out, and guarding for rotating equipment in wet environments.

Business & Safety Benefits

Incident Reduction

Proactive identification and mitigation of hazards before they cause harm or downtime.

Regulatory Compliance

Meeting COMAH, SEVESO, OSHA, and local safety regulation requirements with documented studies.

Insurance Reduction

Lower premiums and improved risk ratings through verified safety management systems.

Operator Confidence

Clear operating envelopes and alarm philosophies that empower safe decision-making.

Safety Performance

200+

studies completed

30%

risk reduction

SIL 1-3

certified designs

Zero

LTIs on projects

Related Pages

Pid Biological Treatment Pids

P&ID development for advanced biological treatment systems: activated sludge, SBR sequencing, MBBR media retention, anaerobic.

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Pid Daf Flotation Pids

P&ID development for DAF and flotation systems: saturator pressure control, air dissolution loops, recycle pumps, flotation cell.

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Pid Flow Diagram Standards

Industry-standard flow diagrams for critical water treatment processes engineering.

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Pid Instrumentation Control

Instrumentation and control system design.

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Pid Process Flow Design

Process flow diagram development for critical water treatment processes systems.

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Pid Standards Symbols

P&ID drafting standards and symbol libraries.

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Need Safety Assessment?

Our safety engineers can conduct HAZOP studies, LOPA, and SIL determination for your water treatment processes.

Industries We Serve

Our expertise spans multiple industries with sector-specific water treatment solutions.