Process Safety Management

We offer a comprehensive suite of Process Safety Services and would love to partner with you on your next project.  We pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety backgrounds. Our specialists understand how plants operate because they have actually worked in covered processes and facilities.   

Services:
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Process Safety Management/Risk Management Plan (PSM/RMP)

Navigating the process of PSM/RMP Program Development and Implementation can be overwhelming. aeSolutions can assist with developing and implementing all elements required by the Occupational Safety and Health Administration (OSHA), PSM Standard, 29 CFR 1910.119, and the United States Environmental Protection Agency (EPA), RMP Rule, Part 40 CFR 68.

aeSolutions has the knowledge and experience to assist with all levels of PSM/RMP development and implementation, from high level gap and applicability assessments to complete PSM/RMP site program development, including drafting procedures and creating mechanical integrity programs.

  • PSM/RMP Program Development & Implementation

  • Risk Management Plan/Hazard Assessment

  • Management of Change (MOC) Program Development & Implementation

  • Incident Investigation

  • Mechanical Integrity Program

  • Operating Procedures & Training

  • Training (PS Leadership, Auditor, PHA/LOPA)

  • Electrical Area Classification

Process Hazard Analysis (PHA)

PHA studies are the core of process safety and risk management programs. They help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property.

PHA also is required by OSHA's PSM (29 CFR 1910.119) and EPA's RMP (40 CFR 68) regulations in the US and process safety and risk management regulations around the world. 

  • Hazard and Operability (HAZOP)

  • What if

  • What-If/Checklist Analysis

  • Failure Modes and Effects Analysis (FMEA)

  • Dust Hazard Assessment

  • Control System Hazard and Operability (CHAZOP)

Quantitative/Semi-Quantitative Risk Assessment (QRA)

A QRA is a specialized approach to assess high consequence LOPA scenarios with large risk gaps to close. Further "pencil-sharpening" in the QRA will verify the severity of the scenario through consequence modeling, as well as the frequency of the scenario through fault tree modelling. Often conservative assumptions made in LOPA are revealed in QRA, which makes the solution to gap closure more practical.

 

QRA will handle conditional dependence among IPL(s) and the initiating cause(s). aeSolutions utilizes commercially available software tools, along with in-house expertise, to facilitate QRAs.

  • Risk Graphs

  • Event Tree Analysis

  • Bowtie Analysis

  • Layers of Protection Analysis (LOPA)

  • Independent Protection Layer (IPL) and Safety Integrity Level (SIL) Selection

  • Implicit LOPA 

  • Safety Layer Matrix 

  • 3D Risk Matrix

Human Reliability/Human Factors

Human Factor Analyses provide qualitative insight to the human factors issues related to the error, and also provide a more accurate quantitative assessment than is found in standard LOPA tables for human performance credits. The ability to model conditional dependence among operator tasks, as well as model potential human recovery factors from errors, makes the HRA a valuable tool. For a typical HRA, a standard operating procedure (SOP) is broken down into discrete tasks. Interviews with Operations are conducted, known as a "talk-through," as well as a plant "walk-through" which covers the equipment of concern from the SOP. PSFs (Performance Shaping Factors) related to each task are discovered. Dependencies among tasks are estimated. Each of these will influence the HEP (Human Error Probability) for each task. Each task is to be modelled as a success or failure. An HRA Event Tree is constructed, each identified task being a branch in the tree, and then solved; the output of which is typically an input to a QRA.

 

aeSolutions has the Human Factors Reliability Experts to handle this task.

  • Human Factors 

  • Human Error Analysis

Auditing

Compliance with evolving regulatory requirements, industry standards, and corporate initiatives can be overwhelming.  aeSolutions offers a comprehensive approach address the definition of scope and objectives, development of workflow process, coordination of onsite activities detailed protocols and reports.  We provide a cross functional team of process safety and risk management elements to perform this essential part of the process safety lifecycle. 

  • Compliance Auditing - PSM, RMP, and Risk Based Process Safety (RBPS)

  • Independent Protection Layer (IPL) Verification

Facility Siting​ & Dispersion Modeling

​A Facility Siting Analysis is intended to evaluate the potential hazards and consequences of uncontrolled releases of flammable and toxic substances; to assess their potential for injuring the occupants of fixed and temporary structures on or offsite; to identify existing safeguards; and to determine measures to reduce the risk posed by these potential events. aeSolutions has trained facilitators to execute the hazard recognition and risk reduction process and experienced modelers that apply the appropriate methodology in line with API 752/753 and industry best management practices for Facility Siting. We provide results that allow your site leadership team to allocate resources more effectively to minimize facility siting risks.

  • Facility Siting Analysis

  • Electrical Area Classification

  • Gas Dispersion Modeling

  • Failure Modes and Effects Analysis (FMEA)

  • Control System Hazard and Operability Study (CHAZOP)

  • Gas Detector Placement