Process safety and machinery compliance
Controlling risks to guarantee security, compliance and industrial performance
We support industrial key players in the identification, evaluation and control of risks linked to processes, equipment and industrial installations.
In a context of increasing complexity of processes and strengthening of regulatory requirements, risk management constitutes an essential lever to ensure the safety of people, the protection of the environment, the continuity of operations and the sustainability of investments.
Thanks to multidisciplinary expertise combining process engineering, equipment design, functional safety and risk analysis, we provide solutions adapted to the energy, nuclear, chemical, metallurgy, waste treatment and new technology industries.
Risk analysis and process safety
We intervene throughout the life cycle of installations:
- Feasibility studies
- Process design
- Detailed engineering
- Commissioning
- Operation and maintenance
- Modernization and revamping
Our objective is to identify potential failure scenarios, assess their criticality and define the most appropriate prevention and protection measures.
Functional Safety
We support our customers in the definition and validation of safety instrumented functions (SIF) and safety instrumented systems (SIS).
Areas covered
- Determination of SIL levels
- Verifying security architectures
- Reliability calculations
- Performance evaluation of instrumented barriers
- Systems compliance review
Our expertise
HAZID – Hazard Identification
Systematic identification of dangers from the initial phases of a project in order to anticipate major risks linked to:
- Industrial processes
- Equipment
- Dangerous substances
- Operation and maintenance operations
- Human-machine interfaces
HAZOP – Hazard and Operability Study
Carrying out HAZOP studies allowing:
- Identifying process deviations
- Analysis of causes and consequences
- Assessment of existing barriers
- Formulating recommendations for improvement
LOPA – Layer of Protection Analysis
Semi-quantitative analysis aimed at:
- Check the effectiveness of safety barriers
- Evaluate the frequencies of occurrence of accident scenarios
- Determine risk reduction needs
- Justify functional safety requirements
Functional Analysis and Failure Analysis
- Functional systems analysis
- FMEA (FMEA/FMECA)
- Failure mode analysis
- Fault Trees Analysis (FTA)
- Event Trees Analysis (ETA)
- Root Cause Analysis (RCA)
Applied standards and standards
Our interventions are based on international best practices as well as recognized norms and standards:
ISO standards
- ISO 12100 – Safety of machinery — General design principles — Risk assessment and risk reduction
- ISO 13849 – Machine safety – Parts of control systems relating to safety
- ISO 17776 – Petroleum and natural gas industries – Offshore platform installations – Guidelines for tools and techniques for risk identification and assessment
IEC standards
- IEC 61508 – Functional safety of electrical/electronic/programmable electronic safety-related systems
- IEC 61511 – Functional safety – Safety instrumented systems for the process industry sector
- IEC 62061 – Safety of machinery – Functional safety of safety-related control systems
Industrial standards
- Seveso/COMAH Directives / Machine / ATEX / Pressure Equipment / EMC /
- INRS/HSE guides
- Good process safety practices
- Requirements of the nuclear, energy and chemical sectors
Sectors of intervention
We support projects in many industrial sectors:
- Energy and electricity production
- Nuclear
- Chemistry and petrochemicals
- Hydrogen and industrial gases
- Lithium-ion batteries and gigafactories
- Waste treatment and recovery
- Metallurgy and heat treatment
- Manufacturing industry
Our services
Advisory and expertise
- Facilitation of risk reviews
- Process safety audits
- Independent risk assessment
- Technical assistance to project owners and operators
Safety Engineering
- Definition of prevention and protection barriers
- Facility Security Architecture
- Functional safety and SIL
- Management of Change
Regulatory Compliance
- Safety documentation and files
- Justification of risk levels
- Support for inspections and audits
- Support for certification procedures
Our Industrial Successes
⚡ Optimization of TABLAMI Equipment (Gigafactory)
Compliance and optimization of a TABLAMI machine for the manufacture of lithium-ion batteries
The Challenge: The strict application of European safety standards caused repeated sudden cuts in electricity and compressed air each time a door was opened for maintenance or adjustment. This rigid approach led to cascading micro-stoppages, heavily penalizing the overall availability of the line (OEE) and degrading the production rate (pieces per minute – ppm).
The Impact: By rigorously applying our 7-step methodology, we orchestrated a surgical retrofit: risk analysis (ISO 12100) and safety recalculation (ISO 13849 PL_r), functional analysis, local modification of the electromechanical architecture and updating of the intelligence of the automation systems.
The Results: Untimely stoppages have been largely eliminated in favor of a smooth and secure production cycle. Capacity increased from 1,000 to 6,000 cells per day in just three weeks after return to service, with stabilized performance at more than 13 ppm during intensive load ramp tests.
Expertise at the service of sustainable performance
Risk management is not limited to regulatory compliance. It constitutes a key factor in competitiveness, availability of installations and protection of industrial assets.
We bring a pragmatic and independent vision, based on field experience, process engineering and international best practices.
Ready to Innovate?
Contact us today to discuss your projects and find out how we can help you.