DEKRA PROCESS SAFETY –

Trusted Advisors for Process

Safety Excellence
 DEKRA Process Safety

Your Global Partner for a Safe World

The breadth and depth of our expertise in process safety makes us globally recognised specialists and trusted advisors. We
help our clients to understand and evaluate their risks, and work together to develop pragmatic solutions. Our practical,
value-adding approach integrates specialist process safety management, engineering and testing. We seek to educate and
grow client competence to provide sustainable performance improvement. Partnering with our clients we combine technical
expertise with a passion for protecting life and assets and reducing harm. As part of the world’s leading expert
organisation, DEKRA, we are the global partner for a safe world.

For over thirty years we have provided specialist

services for the identification, analysis, prevention and
Process
Process Safety management of fires, explosions and accidental
Safety Testing
Management chemical releases in chemical and process industries.

Process
WHY PROCESS SAFETY?
Safety
Processing dangerous chemicals can result in a
Process
Process Safety number of hazards, including the unexpected
Safety Consulting
release of toxic, reactive, or flammable gases
Academy
and liquids. If no reliable safeguards are
implemented, these events can lead to disaster.
 DEKRA Process Safety

Process Design Safety and Risk Management

Risk management is a blanket term covering identification and evaluation of threats, hazards or other exposures to
losses/costs. Assessments utilise a large number of techniques ranging from a detailed Quantitative Risk Analysis (QRA) to
more abstract techniques such as Hazard Identification (HAZID) and Hazard and Operability (HAZOP) studies, which rely
on expertise and judgement. DEKRA Group adopts a flexible approach to risk assessment, which allows the integration of
elements from both hard and soft within an analysis. A risk assessment typically provides the basis on which subsequent
risk management decisions can be made.

Process Safety Management (PSM)

PSM refers to analytical tool used to assess commitment of industry towards its process safety, to ensure understanding
of hazards & risks involved, to assess and manage risks involved. We hold proficiency in PSM consulting services to
various industries including Oil & Gas/ Petrochemical/ Chemical/ Pharmaceuticals/ Agro Commodities/ Textile & Dye
Stuff/Paints/ Bulk Organics/fine chemicals etc. We support industries with Gap assessment, implementation of Process
Safety Management and methods to ensure sustainable PSM solutions as per OSHA at their sites.

HAZID
(Hazard Identification) studies involve identification of hazards and the events, which may lead to risk to either people,
Environment, Asset or companies’ reputation, provides a logical starting point for risk management. Systematic appraisal
of what might go wrong, combined with ranking in terms of severity, gives a structured basis on which to develop the
management strategy.

HAZOP

(Hazard and Operability) studies, which are common in the industry, provide a means to systematically identify deviations
from design. DEKRA Group provides HAZOP services and similar studies in a cost-effective manner. The group’s HAZOP
experience ranges from simple plant items to complete facilities.

Quantitative Risk Assessment (QRA)

(Quantitative Risk Assessment) has been long established in the Oil & Gas industry and combines hazard identification
with an assessment of the frequency and magnitude of hazardous events to determine the risk(s), which is evaluated
against tolerability criteria. Full QRA studies frequently encompass several risk management aspects, e.g. modelling of
system behaviour, system reliability and the effectiveness of safety systems. Conventional QRA has been extended by
DEKRA in applications such as Deconstruction Risk Assessment and Typhoon Risk Assessment depending on the local
conditions and client requirements.

Chemical Reaction Hazards

Chemical Reaction Hazards usually arising from uncontrolled exothermic activity. Many industrial reactions are
exothermic and so overheating can occur. Overheating may lead to thermal runaway that is characterized by progressive
increase in the rate of heat generation, temperature and pressure. The consequences of thermal runaway can be severe,
as the incidents at Seveso and Bhopal have shown. There are a number of means of achieving safe operation of chemical
reactors and controlling the Chemical Reaction Hazards.
 DEKRA Process Safety
Pre Start-up Safety Review
PSSR is a safety review conducted prior to start up (commissioning) of a new or modified process / manufacturing plant to
ensure that installation meet original design or operating intent, to re-assess any potential hazard due to changes during
engineering and construction phase of a project. In other words, it ensures the “Ready for Start-up” status of process
facility/units. DEKRA methodology covers not only equipment, but also procedures and training as part of PSSR.

Vent Design
Emergency Relief Vent Sizing is conducted using method generated from the DIERS (Design Institute of Emergency Relief
Systems) project. Specification of the process control and emergency safety measures required to maintain the plant in a
safe condition (even during a foreseeable process deviation). Determination of how the system pressure is generated
(vapour pressure, gassy or hybrid system). This will determine the type of kinetic data, which needs to be obtained for
relief vent sizing and indicate which vent sizing equations to use.

Safety Critical Elements and Performance Standards

Safety Critical Elements will be defined and identified in accordance with DEKRA criteria. Having identified critical
elements each is assigned performance standards that defines essential measures provided to manage major accident
hazards and events requiring escape, mustering, evacuation, and rescue.

Development of HSE (Safety) Case/ COMAH

The tragic losses incurred at the Piper Alpha disaster in 1988 provided the initial momentum for the formulation of
Offshore Safety Cases in the UK. Since then, HSE Cases have become an industry standard and for many countries a
legislation for identifying potential hazards and evaluating the adequacy of a facility’s safety systems to control and
mitigate these hazards. These “cases”, therefore, provide a basis for arguing for or against offshore developments and, by
highlighting the inadequacies, aid the refinement of the engineering design process. The onshore equivalent of this is the
Control of Industrial Major Accident Hazards (CIMAH) Report which has since been revised and improved upon to Control
of Major Accident Hazards (COMAH) Reports. Having completed numerous HSE (Safety) Cases and CIMAH Reports, DEKRA
has considerable capability and experience for the execution and delivery of these assignments.

Health and Safety Management

DEKRA’s approach to health and safety issues is categorized into hardware elements (e.g. design, equipment, etc.) and
software elements (e.g. maintenance, emergency response, behaviour based safety, etc.). Both approaches are crucial
and complementary to ensure comprehensiveness in assessing the health and safety levels at a facility.

Hazardous Area Classification (HAC)

The HAC exercise involves examination of plant design, operations and equipment, understanding the fire & explosion
characteristics of the dust(s), gas (es) and liquid(s). This would facilitate Identification of sources of dust / Vapour / gas
release in the plant under normal and abnormal conditions, determination of the extent of release, assessment of the
persistence of release, identification of locations where combustible dust clouds and / or flammable vapour / gas
atmospheres are or could be present during normal and abnormal operating conditions. This would lead to Classification
of the system into Zone 0, 1, 2 or non-hazardous zone for flammable gases & liquid handling locations and Zone 20, 21, 22
or non-hazardous zone for flammable solid handling locations and Recommendation to reduce frequency or extent of
release and hence, improving the zone.
 DEKRA Process Safety
Layout Review and Facility Siting
Plant layout and facility siting plays an important part in design and engineering phases of all industrial activity. DEKRA
India professionals help in assessing and finalising the location of various process units, buildings and other facilities; in
order to manage risks arising from explosions, fires, and toxic exposure.

Health Risk Assessment (HRA)

With the advent of a growing number of hazardous chemicals and processes, significant concerns have been raised with
respect to the health and safety of exposed personnel. The HRA is an effective tool that enables the potential hazards to
be identified and recognised so as to ascertain the potential risks to personnel in an effort to reduce the exposure
potential. DEKRA’s approach in HRA is to document the various aspects and characteristics of the workplace associated
with a certain job or task and to use this information as a basis for analysing and prioritizing actions to address
occupational health and safety risks.

Emergency Response Planning (ERP)

A key component in safety management is preparedness and anticipation for any untoward situation or circumstance.
The ERP then serves as a vehicle to address the level of preparedness and anticipation in light of possible emergency
scenarios. Through an extensive examination of the processes, materials and systems at a facility, DEKRA India can
explore the various emergency scenarios and establish the required actions. The ERP will therefore articulate specific
responsibilities and action needed under various emergencies. A comprehensive and detailed ERP demonstrates the
capability of a facility to adequately anticipate and respond to emergencies thereby enhancing the reputation and
integrity of the organization.

Dust Hazard Assessment (DHA)

For industries handling flammable / explosible powders, we provide consulting support and can carry out integrated
Safety Management for them in handling powders and dusts and ensuring prevention / mitigation of dust explosions. The
Safety management for dust handling is designed as per NFPA-652 and ATEX guidelines.

ATEX Assessment
The ATEX Directive requires the employer to demonstrate, that he has taken all technical and/or organisational measures
to reduce the risk from dangerous substances, so far as is reasonably practicable. Where the nature of the activity
precludes elimination of the risk, the employer should remove initiation events, such as sources of ignition, and install
equipment to mitigate the detrimental effects of an explosion or other energetic event. Where necessary these measures
should be combined and/or supplemented with measures to prevent the propagation of explosions. DEKRA India has
developed a comprehensive phase-wise approach that works in partners with the employer to achieve compliance in a
focussed and efficient way. These phases include Initial Assessment; Detailed Studies (such as Fire and Explosion
Assessment, Electrostatic hazard assessment, etc.); Overall Risk Assessment and Verification & Documentation.

Electrostatic Hazard Assessment

Electrostatic discharges (sparks) can also trigger fires and explosions in industry. The consequences of a fire or explosion
can range from disruption of production to loss of plant and injury or fatality of personnel. DEKRA can help in carrying out
Electrostatic Hazard Assessment covering the possibility of Electrostatic charge generation, charge accumulation and
Discharge Mechanism. Adequate measures are suggested in order to minimise Electrostatic risk.

Electrical Safety Audit

It involves auditing of electrical work and related electrical safety systems of any industry to ensure its compliance with
the legislative requirements specified for that respective industry. DEKRA conduct the audit as per the National Building
Code, Electricity Act, Electricity Rules, Indian Standards, and Recommendations & Guidelines from Institute of Electrical &
Electronics Engineers.
 DEKRA Process Safety
Fire Safety Audit
Fire Audit can be used as a tool for focusing attention on what is important to fire safety. In every industry, there are
wide range of work activities and materials that have the potential to cause workplace fire, which may result into loss of
human life or property & production loss. These need to be reduced by assessing the Fire risk and taking preventive or
mitigative measures. Additionally, it is important that fire safety precautions are in place including the emergency exits,
fire escape routes and the firefighting equipment. DEKRA checks the adequacy of the existing fire prevention and
protection systems at the facility and accordingly take further actions for further improvement.

Machine Safety
Machine Safety is specialized consultancy for the operations / maintenance of machines in industry as per BS EN ISO
13857, EN 1037 BS EN 1088. It involves identification of hazards associated with the machines used in the industry.
Control measures and risk levels are assessed for effective control of the hazards. As a safety measure DEKRA carry out
Incident history data, Machine hazards, Machine Safety and interlocking for the machines.

Human Factors

Human factors are increasingly being recognised as a significant risk management concern. As systems in general become
more reliable, better-understood and controlled human factors are rising in relative importance. Through its human
factors capability, DEKRA Process Safety has provided necessary emphasis and attention to the suitability of personnel to
the tasks at hand and the resulting outcomes.

Behaviour Based Safety

Behavioural Safety provides with a way of reducing lost-time injuries, through the analysis of your current environment,
and the implementation of proven performance management methods. In other words, Behavioural Safety is the
systematic application of psychological research on human behaviour to the problems of safety in the workplace.

Accident Investigation
Reducing the occurrence of accidents is a key goal in achieving commercial and technical objectives at a facility. However,
accidents inevitably still do occur and must be investigated to ascertain their causes and contributory factors. DEKRA
Group’s specialist capability in this field provides the mechanism and mediums to identify key problem areas within the
operation and to allow mitigation strategies to be formulated to improve personal safety.

Safety Assurance Strategy (SAS)

A thorough review of Safety Management System, its awareness level at various level of employees, its implementation
status leading to gap analysis. With the gaps identified, an implementation plan with responsibilities defined.
Development of local team in client organization who can take if forward internally thereby, over a period of time,
removing the overall dependence on consultants. Mainly carried out in 3 phases, gap identification & implementation
plan, team development & actual implementation and sustainability audits.

Human Factors
Human Factor is the scientific discipline concerned with the understanding of interactions among humans and other
elements of a system. Human Factor applies theory, principles, data and methods to design in order to optimize human
well-being and overall system performance. Human factors are increasingly being recognised as a significant risk
 DEKRA Process Safety
management concern. As systems in general become more reliable, better-understood and controlled human factors are
rising in relative importance. Through its human factors capability, DEKRA Process Safety has provided necessary
emphasis and attention to the suitability of personnel to the tasks at hand and the resulting outcomes.

Training
The DEKRA Process Safety Academy provides training in all areas of process safety and critically embeds and supports
classroom learning with a range of peripheral support activities designed to ensure that internal competence is
developed, demonstrable and sustainable. To this end, we incorporate various learning methodologies, including public
courses and events, tailored in-house courses, e-learning and computer-based training and competence development
programs.

Reliability, Availability, and Maintainability

The risk to project is significantly influenced by failure of key component or systems. For example for a plant:
 Failure of key component contributes to down time and thus productivity; where as
 Failure of a safety system can significantly increase the safety risk.
DEKRA India has assessed Reliability, Availability and Maintainability (RAM) of systems in the management of risk. DEKRA
India applies the relationship between RAM and risk by systematically modelling the inter-dependency of different
elements of a system. These models can be developed in either dynamic or static RAM model, where the selection of the
modelling depends upon the risk contributors to be investigated, and the level of risk it may pose on a project.
DEKRA Group has helped its clients in performing the following key services:
 Failure Mode, Effects and Criticality Analysis (FMECA);
 Reliability Assessment of Instrumented Protection Systems such as Overpressure Protection Systems;
 Reliability Assessment of a High Integrity Protection Systems (HIPS);
 RAM assessment of the production plants on off-shore installations;
 RAM assessment of the on-shore plants;
 Safety Integrity Level (SIL) Assessment.
 Instrumented Protection Function (IPF) Assessment.

Failure Mode and Effects Criticality Analysis (FMECA)

FMECA provides a structured and meticulous approach to identify possible failure modes, their preceding events, the
resulting effects and opportunities to design out these eventualities. In identifying potential failure scenarios, the FMECA
provides proactive planning opportunities. In essence, it provides the following benefits:
 A tabulation of all operating equipment at a facility;
 Identification and documentation of failure modes of each equipment;
 The resulting effects of such failure modes on the failure potential of the overall system; and
Development of a criticality ranking for each failure mode, which provides the basis for establishing preventive
maintenance and sparing philosophies as well as redundancy configurations.
 DEKRA Process Safety
Safety Integrity Level (SIL)
The integrity of a facility/system can be evaluated in terms of the adequacy of its control measures and safeguards in
place. This is the principle behind the SIL assessment which allows a facility/system to be assessed and graded according
to different classifications. SIL classes can then provide the basis for determining if additional measures are required (in
light of the criticality of a system) or conforms to the stipulated level of safety. The resulting benefits from such an
assessment include:
 Consistent evaluation of each system based on the SIL classification;
 Derivation of individual SIL classes for each system;
 Integration and derivation of individual SIL classes to obtain the overall SIL class for the facility;
 Demonstration of the SIL class in light of compliance requirements.

Reliability, Availability and Maintainability (RAM)

 Dynamic RAM is an efficient method for reducing design, operations and contractual cost of projects by means of the
following:
 It ensures that return on investment is as per expectations by ascertaining the design requirements to meet
contractual productivity target;
 It assesses the changes in CAPEX required for different levels of redundancy and sparing, and trade this off against the
OPEX costs develop maintenance and sparing strategies;
 It confirms the redundancy of different system elements;
 It predicts productivity shortfall;
 It can help assess and develop make-up strategies upon expected shortfall in productivity;
 It can determine operational constraints;
 It can define spares locations, supply logistics and storage cost;
 It can develop commonality of spares and help reduce investment in spares holding;
 It can define resource allocation and hence help assess resource requirement to meet target productivity;
 It can define maintenance schedules in line with the target or contractual productivity; and
 It can include cost of maintenance and repairs in the model to help assess cost profile over the life of a facility.

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DEKRA India Pvt Ltd.

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Email: info-in@dekra.com Ph: +91-22 66942350 Tel : + 91 40 23 04 69 44