Process Safety Management

Turn Your Process Risk into Safe Systems with Actionable Data-Driven HAZOP Studies

Sigma-HSE will turn your process safety concerns into clear, manageable actions. We’ll deliver a complete HAZOP that strengthens workplace safety, supports compliance, and builds operational confidence.

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The safety of your employees from process-related hazards is your responsibility

Process deviations, design flaws, or operability issues can lead to serious incidents. As a duty holder, you have a legal obligation to identify and mitigate these risks

STRUCTURED HAZOP STUDY EXPERTISE

Take control of your process safety with our HAZOP studies

Our HAZOP study approach will guide you and your team throughout your hazard and risk identification and management journey. Using data gained from your study, we’ll empower you to make future proof design and operational decisions.

End-to-end support: from workshop preparation to action follow-up, our experienced HAZOP facilitators are at your side for every phase of your project.

Collaborative and efficient: our chairs will guide your design, engineering, and operations teams to uncover hazards and operational weaknesses.

Actionable insights: our HAZOPs produce practical, prioritised outcomes that help you meet regulatory expectations and internal risk goals.

Sigma-HSE will work closely with your team to deliver a HAZOP study shaped by the specificities of your plant layout, process design, and risk profile.

PROCESS CONFIDENCE

Protect uptime and avoid disruption to your process and business operations

Our HAZOP studies are created to align with your operational plans and objectives. We aim to reduce process disruption with a streamlined approach that gets useful data to you, fast.

Get a quote in days: we respond quickly with tailored HAZOP quotes and clear next steps, so that we can deliver efficient studies that fit your schedule.

Focused facilitations: we’ll work with your operators, engineers, and management in a clear, collaborative process that respects your internal culture while cutting through any internal noise.

Clear outputs: from P&ID review to report submission, we streamline your HAZOP study into a focused, professional process that prioritises efficiency without compromising on rigour.

Sigma-HSE will complete your HAZOP study while avoiding bottlenecks and overruns. Reports and a separated actions list will be clear, risk-prioritised and proportional.

PRICING TAILORED TO YOUR PROJECT

Achieve thorough, regulator-ready HAZOPs with Actionable Outcomes

Poorly scoped or weakly facilitated HAZOPs can miss critical risks, trigger costly redesigns, or fail regulatory scrutiny. Our bespoke studies are always sized to your scope and risk level.

Value-led delivery: our team brings decades of real-world process safety and regulatory experience, with outputs that are designed to support legal requirements, PSM audits, COMAH/DSEAR reports, and internal governance.

Beyond the minimum: we don’t cut corners. Every HAZOP we run is thorough, insightful, and aligned to international best practice (IChemE, IEC 61882).

No hidden fees: your quote is your quote. We don’t believe in hidden fees or admin charges.

Sigma-HSE delivers credible, high-quality HAZOP studies tailored to your technical requirements, compliance obligations, and business priorities.

Design and Build Resilient Processes and Operations with our HAZOP Study Methodology

Our HAZOP studies provide a systematic and collaborative evaluation of potential hazards within your plant or process. Our experienced facilitators will identify deviations, assess risk, and identify any gaps in your risk management—delivering a clear, actionable report designed to allow you to strengthen safety, support compliance, and optimise operational performance.

Defining the Scope

We’ll start the study by precisely identifying what your HAZOP will cover. Although bespoke to you, scope typically includes systems, units, or phases of a project. Objectives are then set which can range from identifying hazards in a greenfield design to verifying controls in a process upgrade. Our clear definitions will anchor the study to ensure alignment across the team.

Process Deviation Analysis

To keep the analysis focused we’ll then divide your process into defined “nodes” such as pipelines, vessels, or control loops. HAZOP uses guidewords such as No, More, Less, and Reverse, in combination with process parameters, to explore each node to identify hidden hazards and failure scenarios. This recognised and powerful method will ensure clarity; delivering a thorough and systematic HAZOP.

Analysis of Causes and Consequences

For each process deviation identified, we’ll then guide the team through a structured discussion of potential causes i.e., valve failure, sensor error, or operator misstep. These root causes are then linked to downstream consequences like equipment damage, production loss, or safety risks. This analysis will provide a clear understanding of how each deviation could impact people, operations, and the environment.

Actionable HAZOP Documentation

Every HAZOP we deliver comes with a structured, peer-reviewed report that captures all identified deviations, associated risks, and agreed actions. Our documentation is designed to be easily interpreted by your operators, engineers and managers. We’ll ensure responsibilities are assigned, follow-up actions are prioritised, and the report becomes a practical tool for your ongoing risk management and regulatory compliance.

Our HAZOP studies always include the below as standard:

Independent, qualified and experienced chair and scribe

Batch and continuous processes

Node (HAZOP) and System (HAZID) definition prior to workshops

Use of dedicated recording software

Optional Risk Ranking (both raw and residual). Useful for ALARP demonstration and Integrity Level Assessment

Separate prioritised actions/recommendations report, in Excel to allow easier export to a tracking system

Option for actions/recommendations review meeting/follow-up

Get a Free HAZOP Consultation

Fill out the form below and we’ll be back in touch within 24 hours.

We’ll be your guide throughout your HAZOP journey.

Systematically optimise and protect your processes.

Machine Manufacturing

HAZOP for High-Temperature Machine Manufacturing Process

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Chemical Manufacturing

Process Safety Transformation for Chemical Manufacturing Company

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Speciality Chemical

“The team at Sigma-HSE are professional, efficient, responsive and completed a thorough and detailed assessment of our process.”

HAZOP Study Solutions for your Industry

Our dedicated team consists of HAZOP leaders, scribes and technical engineers with specialist process and process safety knowledge. With each member having multiple years of industry experience, they can apply the HAZOP methodology across a range of industries and businesses. This includes industries such as:

Aerospace

Agrochemicals & Pesticides

Pharmaceuticals

Paper Manufacturing

Wood Processing/Wood Workshops

Chemical Manufacturing

Machinery Manufacturing

Commercial/Residential Buildings

Textiles Manufacturers

Food & Beverages

Transportation & Logistics

Paints & Solvents

Warehousing & Storage

Mining, Oil & Gas

Animal Products

Research & Development

Start your HAZOP Journey in a Few Simple Steps

Contact us

After you get in touch, a member of our team will reach out to scope your current operations and see how most effectively we can undertake a HAZOP study.

Study

Our consultants will visit your site or start an EHAZOP process to evaluate and verify all your safety procedures, equipment and control systems.

Documentation

Our consultants will issue a HAZOP report after the study is complete. Although each report will differ, it will contain an actionable roadmap.

Post-project support

If necessary, our consultants will follow up to make sure that their recommendations have been applied and that you have a clear understanding of the rationale behind the report.

Prevent catastrophic failure.

Gather deeper risk visibility.

Safeguard your operations.

Reduce operational risks and enhance your process safety with a HAZOP from Sigma-HSE

Frequently asked questions

Why undertake a HAZOP?

The HAZOP study is used to identify potential dangers and operability problems concerning technological and organisational objects that have the potential to deviate from the original design intent. The study is completed using an analysis of the resistance of an object to artificially modelled deviations.

It does this by applying simple guide words (for example, More-Less, None etc) to process parameters (for example pressure flow, temperature, concentration etc) in a robust and systematic manner.

What is the time frame for completing a HAZOP?

A HAZOP should be conducted during the early stages of process design where all possible desirable and undesirable behaviours of the system are applied. The design should essentially have been determined and fixed, and fully represented in the form of a Process and Instrumentation Diagram (P&ID).

At this stage, the detailed design and specific process equipment items will be known (for example, the type of pump used; maximum pressure and flow rate that the pump can deliver, materials for construction of the pump etc). The obtained data during this study will help industry experts to ensure timely responses to potential dangers and make necessary adjustments to the project to eliminate the possibilities of residual risks in later design stages.

The methodology ensures that the process, its potential deviations, and the protection systems employed to ensure safety are fully understood by the business.

What happens during a HAZOP study?

During a HAZOP study, a team of specialists from various scientific disciplines work under the leadership of a HAZOP chair/HAZOP leader/HAZOP facilitator to systematically examine relevant parts of a project or system. These experts may include those with specialist mechanical engineering knowledge, process safety knowledge and design engineers.

The HAZOP applies different methodologies that are suitable for potential hazard identification and health problems. This may include checklists and the analysis of the types of dangers and consequences of failures. Based on the study, experts then prepare final documentation for business projects.

What happens after a HAZOP study?

After undertaking a HAZOP, specific scenarios are generated and then prioritised by risk.

With a selection of safety, prevention, control and mitigation measures recorded, outputs can then be used to analyse multiple scenarios before the potential use of any further studies (for example, Layers of Protection Analysis (LOPA)) to ensure the effectiveness and integrity of the measures appropriately meet recognised risk tolerability criteria.

Do you offer online HAZOP solutions?

Sigma-HSE offer onsite and online HAZOP strategies and solutions with our experienced technical consultants.

Our leaders have a vast array of knowledge and expertise in industrial process safety which they bring to HAZOP leadership.

Online HAZOPs have the added advantage of bringing together teams from different sites and different countries to share their knowledge and understanding of common process issues without lost travel time or accommodation expenses.

Our other online solutions for process safety also include HAZID, What-If, LOPA sessions, FERA, QRA, Dispersion and Consequence Modelling, desktop HAC, ATEX Compliance and DSEAR assessments for new and existing plants.

How can Sigma-HSE help?

Sigma-HSE offer on-site and online HAZOP strategies and solutions with our experienced technical consultants. Our leaders have a vast array of knowledge and expertise in industrial process safety which they bring to HAZOP leadership.

Our dedicated HAZOP team consisting of leaders, scribes and consultants with specialist process knowledge have years of industry experience and can apply multiple techniques across a range of industries and businesses.

We have undertaken studies across the full range of the processing industries (chemicals, pharmaceuticals, explosives, food & hygiene, waste, onshore oil & gas, etc) and processing operations (chemical reaction technology, storage and transfer systems, incineration systems etc).

Our team of experts is committed to helping you ensure and maintain compliance without the exorbitant fees and delay to your operations.

We also offer bespoke HAZOP training packages to aid in developing your hazard identification understanding.