HAZOP

• New process involving thermally unstable materials and exothermic reactions. All operations from reaction to drying using ALARP based risk targets
• New Grignard-based process from reaction to drying with significant reaction hazards
• Review of project involving hydrogenation, pyrophoric materials, hydrogen evolution, water reactive chemicals, exothermic and gas evolving reactions, as well as flammable solvents and potent/high toxicity compounds. All operations from reaction to drying.
• All powder handling operations (drying, sieving, milling) in a facility involving 9 different products
• Review of new tank farm involving over 20 tanks and 14 different solvents. 
• New Filter/Dryer project including cleaning and decontamination cycle as well as normal processing
• Update and Revalidation of HAZOP for spray drying facility in new location
• Hydrogenation processes involving pyrophoric catalysts, exothermic reactions and water reactive chemicals
• Highly reactive process in a flexible pilot plant context
• Carbon Air Abatement System
• New Thermal oxidiser and Vent Collection System
• Utilities (chillers, purified water systems etc.)
  

Layer of Protection Analysis (LOPA) & SIL

• LOPA review of 50+ major accident scenarios for a new process involving runaway reaction and thermal decomposition hazards
• Review of Safety Integrity (SIL) methodology and practice on behalf of a major pharmaceutical facility. Proposed revision of SIL methodology to ensure greater consistency with the HAZOP process
• LOPA and SIL allocation study on scenarios involving thermally unstable materials and exothermic reactions
• LOPA study of scenarios involving vapour cloud explosions and reaction runaways
• LOPA study on a Grignard process with scenarios involving significant exotherms and gas evolution
• LOPA study of powder handling: charging, drying, sieving, milling etc. for St-3 and low MIE materials
• LOPA study for scenarios involving explosive thermal decomposition during distillation
  

Seveso/COMAH

• Update of the Seveso Safety Report on behalf of bulk pharmaceutical manufacturer. Identification of major accident hazards (MAH’s), selection and development of representative cases, consequence modelling and likelihood analysis, as well as update and review of entire document
• Risk Assessment for major biopharmaceutical facility
• Major Accident Hazard Identification for new Facility on Top-Tier Seveso site.
• Fault Tree Analysis and Consequence Modelling using for runaway reaction and thermal decomposition hazards

Thermal Oxidation

• High Level Review of a proposed Thermal Oxidiser Project on behalf of a bulk pharmaceutical facility. Addressed sizing (including opportunities for reduction at source), safety philosophy, and suitability of proposed technology
• Review of an RTO system failing to meet TOC and odour emission specifications

Vent Collection Safety & Vent System Trip Reduction

• Vent collection study for API manufacturer to determine the optimum safety and operational configuration for connection of an existing facility to a new Thermal Oxidiser
• Revised safety philosophy and proposed reduction at source measures to avoid spurious safety system trips and to meet EPA concerns, based around German standard TRbF20 and NFPA 69
• Reviewed design and safety philosophy of vent system and Regenerative Thermal Oxidizer to avoid spurious safety system trips. Proposed removal of interlocks shown to be unnecessary per  NFPA 69, TRbF 20 and EN 12753

Hazardous Area Classification

• Site wide Review of Hazardous Area Classification at a major pharmaceutical facility per IEC 60079 and IEC 61241
• Assessment of effect on HAC of reduced ventilation for facilities handling flammable materials and combustible powders per IEC 60079, IEC 61241, NFPA 497,  and IP 15.
• Determination of zone types and extents (including IIC) using applicable standards
  

Green Energy Technical & Economic Appraisal

• Proposed €15m Waste Plastic to Diesel Pyrolysis facility
• Major €100m Waste to Ethanol project involving Gasification and novel technology
• Waste to Methane and Compost
  

Management Consulting

• Enterprise risk identification for HSE funded organisations
• Business Continuity Planning including Business Impact Analysis and Risk Assessment for a pharmaceutical company
• Transition programme for upgrade of project delivery function of international NGO
• Organisational review and transition plan of all operations for a health sector agency
• Review of structures and systems for an international NGO
• Troubleshooting of procurement and delivery processes for a major international food company

Other

• Review of safety incidents and development of an action plan for improvement of safety compliance at a major pharmaceutical facility
• Assessment of the suitability of an existing  scrubber for new chlorine scrubbing duty