Process Safety

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Unique Safety Training Program & Audits For Workplace Safety


Process Safety

Safety is NOT an expense, but its an investment to ensure your employees are safe, you have continuity or minimal losses in production, and the reputation of your company stays up. It is sometimes mistaken as a deterrent to making a profit. Process safety focuses on Hazard Identification, technical evaluation & engineering controls to prevent incidents and loss. Chemical storage & processing Plants, Refineries, Oil & Gas processing facilities have inherent risks associated with them, given chemicals are flammable, toxic, corrosive, reactive, etc. Additionally, during processing, chemicals are most often energized at higher temperatures or pressures, thereby increasing the hazards associated with them and risks as well.

Aggie Safety, with the cumulative experience of its team of experts of close to 40 years can help your facility with the following Process Safety support:

  • Process Safety Management (PSM)
  • Risk Management Plan (RMP)
  • Facility Audits/Inspections
  • Pressure Safety Valves design and validations
  • Process Hazards Analysis
  • Combustible Dust Hazard Analysis
  • Incident/Accident Investigation
  • Electrical Classification
  • Mechanical Integrity
  • Management of Change/ Pre-start reviews

Risk Management Plan (RMP)

In today’s complex industrial landscape, safety is paramount. A Risk Management Plan (RMP) is an essential component of ensuring the safety and well-being of your employees, the surrounding community, and the environment. Let’s delve into what RMP is all about.

Facility Audits/Inspections

Process Safety Management (PSM) is a systematic framework designed to prevent and mitigate catastrophic incidents in facilities that handle hazardous chemicals. It encompasses a range of practices and procedures that focus on identifying, understanding, and managing the risks associated with these chemicals to ensure the safety of both employees and the surrounding environment.

Process Safety Audits/Inspections

Process Safety audits must be conducted by independent outside 3 rd party/consultants in order
to ensure a cold eye review/unbiased review of policies, procedures, and safety management
systems. AGGIE SAFETY can be a partner to your needs by utilizing its experts. The following work
Lone Star follows process to conduct an impactful audit for your facility:
 A thorough inspection/field assessment of your facility
 Employee interviews are conducted during the process
 Facility documentation, including training is reviewed/spot checked
After inspections/field assessments, a detailed report to the customer is provided with
following key aspects:
 Issues and concerns not meeting OSHA/RAGAGEP requirements
 Recommendation from AGGIE SAFETY experts to mitigate the issue and meet
the OSHA requirements
 Actual CFR code/Other requirements for item not meeting requirement

Process Hazards Analysis

AGGIE SAFETY experts can provide Process Hazards Analysis Support following requirements & best
practices as mandated by OSHA. ‘
Some of the critical aspects followed by AGGIE SAFETY experts for PHAs for our customers are as
 Following correct methodologies
 Evaluating all applicable Process Hazards
 Reviewing previous incidents at the facility
 Evaluating Engineering controls and their failures
 Evaluating Administrative controls and their failures
 Facility Siting

Dust Hazards Analysis

Aggie Safety experts are DEKRA trained and certified and, with their industry experience in Solids Handling, can provide Dust Hazards Analysis (DHA). OSHA, with its Combustible Dust National Emphasis Program (NEP) put in place after the Imperial Sugar incident and several iterations and applicable CFR is concerned with the presence of hazards and hazardous conditions, not if the employer has performed a DHA. DHA analysis is helpful to employers in making informed decisions regarding housekeeping procedures, administrative controls, engineering controls, personal protective equipment specifications, employee training needs, and other safety-related issues.

Explosion Protection & Electrical Classifications

Aggie Safety experts can support hazards associated with flammable atmospheres in a facility, explosion likelihood, controls around those hazards, and electrical classification requirements.
Aggie Safety experts are well aware of the implementation of the following industry codes/standards:

Mechanical Integrity

Equipment if not maintained, is never reliable and its failures can lead to accidents/incidents which can
impact human lives, company assets, production, revenue, and company reputation.
AGGIE SAFETY experts with their background in the Oil & Gas and Petrochemical Industries can help
facilitate the following:
 Setup or validate a Mechanical Integrity program of a facility.
 Ensure applicable categories of equipment are covered in the Maintenance program.
 Ensure applicable codes are followed for equipment categories.

Pressure Relief Systems

Aggie Safety experts can support Pressure Relief systems for new Design or Validation for
existing systems. Aggie safety has ~ 30 years of cumulative experience in this kind of specialized work, which requires thermodynamic knowledge of fluid being handled as well as mechanical aspects of how
pressure relief systems work. Aggie safety professionals are well-versed in the implementation of the following
Industry codes/standards:
 ASME Section VIII Div 1, Div 2, Div 3, ASME 31.1, ASME 31.3
 API specifically API-520, 521, 526, 527, 537, 576, 620, 650, 2000
 CSA S-1.1, S-1.2, S-1.3
Based on vast experience, Aggie Safety professionals can work with your company and come up with
cost-effective mitigation solutions for existing plants with some of the most common deficiencies in
existing systems as follows:
 PSVs being undersized
 Scenarios (Contingency) being missed
 PSV Inlet or Outlet pressure drops exceeding API limits
 High back pressure issues on sub-header/header systems
 Too conservative assumptions on existing scenarios

Management of Change/ Pre-start reviews

In any dynamic work environment, change is a constant. Managing change effectively is crucial to maintaining safety, operational efficiency, and regulatory compliance. Management of Change (MOC) and Pre-start Reviews are indispensable tools in this process.

Invaluable on-site support for project Oil& Gas . Engineering . Power . Roofing . Construction .

Headquatered in Houston

Professional Excellence

Extensive knowledge and experience in the field of occupational safety and health to help organizations improve their safety programs and create a safer work environment for employees. Our programs feature ongoing reviews and consulting, record keeping & document retention, safety manuals, checklists, process & procedure development, codes & standards compliance and more.