Background
Following the successful completion of Hazardous Area Inspections by our E, C & I Site Services team, a leading super absorbent material production company partnered with us to provide Process Safety expertise.
The client is a global manufacturer offering an extensive range of industrial packaging products, serving diverse industries worldwide, including medical dressings, sanitary products, food packaging, oil/fuel filtration, and cable.
Initially, F.E.S. (EX) was contracted for Hazardous Area Inspection services by this client. This initial engagement has since evolved into our support with their Process Safety activities.
Project Scope
F.E.S. (EX) expertise was requested to support the client in Process Safety Management, including specialist Process Hazard Analysis (HAZOP/LOPA) and Regulatory Compliance regarding DSEAR/ATEX. The client sought to relocate their methyl acrylate (MA) storage and delivery system this included:
- MA delivery system
- Storage tank
- Recirculation loop
- Downstream distribution into the super absorbent material production facility
Methodology
The Process Safety team began by performing a DSEAR assessment to identify existing hazards related to explosive atmospheres and contribute to an inherently safe process design. The framework of Risk Management was applied as per BS EN 61508. This process involved:
- Identifying Process Hazards and Suitable Safeguards:
- A thorough analysis to pinpoint potential hazards.
- Determination of appropriate safeguards to mitigate these hazards.
- Quantitative Analysis:
- Conducting detailed calculations to define and identify the necessary protection and mitigation levels for each hazardous scenario.
The process and plant description were initially reviewed by the HAZOP leader, and a list of nodes (operations with specific design intent) was developed by the facilitator and the site team. This list was then modified during the study to incorporate additional information as it was received. This project required specialised expertise in both Risk Assessment and Process Engineering. The structured approach ensured that the client’s methyl acrylate storage and delivery system was transferred with the highest safety standards in mind.
Outcomes
Following the completion of the work, Dipl-Ing. Fatih Topcu remarked:
“I have worked on this type of project often in recent years. HAZOP/LOPA projects are always challenging because they require the full expertise of a Process Safety professional in technical concepts, process safety management, and compliance. We identified multiple safety gaps and potential areas of improvement during the studies, significantly contributing to an inherently safe design at an early stage of the project. The client is happy with the result, and so am I.”
The client’s Engineering Supervisor praised the collaboration:
“Working with F.E.S. has been a pleasure. Our company is currently engaged in a project working with F.E.S. from the initial HAZOP and LOPA studies right through to project design and implementation stages. The company is very professional and most importantly their employees are very knowledgeable. The outcome provided us with a high standard of risk assessment analysis, combined with the company’s present and historical knowledge.”
The successful partnership between F.E.S. (EX) and the manufacturer underscores the importance of specialised expertise in Process Safety Management and Risk Assessment. Through a thorough DSEAR assessment and detailed HAZOP/LOPA studies, F.E.S. (EX) ensured that the client’s methyl acrylate storage and delivery system was relocated with optimal safety and efficiency.
For more information about our Process Safety Management services, or to schedule a consultation, please contact us to speak with one of our team members.