Process Safety

Process safety

How confident are you in your facility's safety systems?

Manufacturing safety requires more than basic protection. BSI Engineering's process safety team develops comprehensive solutions that identify hazards, prevent incidents, and protect your operations through systematic analysis and innovative design.

Request a consultation

Workers in safety vests operating control stations

Safety analysis leadership

Understanding that underlies safety

Process hazard assessment

Understanding risks drives effective protection. Our safety engineers conduct detailed Process Hazard Analysis (PHA) studies that systematically identify potential hazards in your operation. We evaluate process conditions, equipment reliability, and human factors to understand risk scenarios. This thorough analysis forms the foundation for developing appropriate safety measures.

Risk assessment innovation

Not all hazards present equal risk. Our systematic approach helps you understand both the likelihood and consequences of potential incidents. We apply industry-standard methodologies including LOPA (Layer of Protection Analysis) to evaluate risk levels and determine required protective measures. This risk-based approach helps focus resources where they provide maximum benefit.

Protection system design

Safeguards that never sleep

Safety instrumented systems

Critical processes need reliable protection. Our engineers design Safety Instrumented Systems (SIS) that provide appropriate risk reduction for your operation. We select appropriate architectures, specify reliable components, and develop testing strategies that ensure system performance. This comprehensive approach helps prevent incidents while maintaining operational flexibility.

Emergency response leadership

When incidents occur, quick response is essential. We develop emergency shutdown systems that safely bring processes to a stable state. Our designs include:

Automated shutdown sequences
Manual emergency stops
Containment systems
Relief system design
Ventilation controls
Emergency power provisions

Implementation support

Safety systems secured

Documentation

Safety system success requires clear communication. Our team develops comprehensive documentation including:

Safety requirement specifications
Detailed design documents
Operating procedures
Maintenance protocols
Testing requirements
Training materials

Implementation support

Validation leadership

System performance must be verified. Our engineers:

Develop test procedures

Oversee installation verification

Conduct functional testing

Document system performance

Train operators and maintenance staff

Establish periodic testing protocols

Ongoing safety management

Protection that persists

Management system support

Safety requires continuous attention. We develop comprehensive process safety management programs integrated with rigorous change management procedures to maintain operational integrity. Our incident investigation protocols ensure thorough analysis of any safety concerns while regular safety audit programs verify compliance. Through detailed training requirements and robust documentation systems, we help maintain your safety culture.

Compliance innovation

Regulatory requirements drive safety programs. Our team ensures full alignment with OSHA Process Safety Management requirements while meeting EPA Risk Management Planning standards. We integrate industry consensus standards and insurance requirements into cohesive programs. Through careful attention to local regulations and corporate standards, we help protect your operation and your people.

Industrial workers in safety gear operating manufacturing equipment

Contact

Ready to enhance your safety systems?

Contact BSI Engineering to discuss how our process safety expertise can help protect your operations.

Request a Consultation