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Our Solutions: Consulting

Preliminary Hazard Assessment

Engineer conducting Preliminary Hazard Assessment at a manufacturing site.

What Is a Preliminary Hazard Assessment?

A Preliminary Hazard Assessment is an initial on-site evaluation that examines potential safety risks in industrial operations. Our experienced engineer will walk through the operations and talk to employees managing and handling the process of concern, which normally involves a flammable or highly hazardous chemical or combustible dust. We will provide a list of samples to take, tests to conduct, and the first tasks to complete toward compliance, as needed. The engineer will spend time on-site reviewing operations and talking to employees. The preliminary hazard assessment will provide input to either a Process Hazard Analysis or a Dust Hazard Analysis as the material properties dictate.

Key Steps in the Preliminary Hazard Assessment

During the assessment, our experienced engineers:

  • Meet with facility personnel to review operational procedures and safety protocols

  • Examine process areas to identify potential hazards and risk factors

  • Document material handling practices and existing safety measures

  • Develop a comprehensive sampling and testing strategy

  • Create an action plan aligned with compliance requirements


For facilities managing combustible dust, our assessment aligns with recognized and generally accepted good engineering practice (RAGAGEP) standards under NFPA 652. This framework addresses four essential components:

  • Material combustibility and explosibility evaluation

  • Fire, flash fire, and explosion risk assessment

  • Hazard management strategies

  • Employee hazard communication protocols

Benefits of Preliminary Hazard Assessment

A Preliminary Hazard Assessment serves as the first step in developing effective safety programs for industrial facilities. This systematic evaluation helps organizations understand their risk landscape and build practical safety strategies.

Proactive Risk Management Early detection of potential hazards in operational processes allows facilities to address safety concerns before they escalate. Through early intervention, organizations can implement preventive measures and maintain safer operations.

Financial Benefits Organizations experience reduced costs through planned safety improvements and lower insurance premiums due to documented safety practices. By preventing operational disruptions and efficiently allocating resources, facilities maintain both productivity and profitability.

Operational Improvements The assessment leads to enhanced process efficiency through better equipment maintenance, improved material handling procedures, and streamlined workflows with integrated safety controls. These improvements support both safety goals and operational excellence.

Compliance and Documentation The assessment aligns operations with industry standards while developing comprehensive safety documentation. This ensures facilities maintain their compliance status and are prepared for regulatory inspections.

Strategic Planning The assessment provides direction for safety program development and creates a foundation for Process Hazard Analysis or Dust Hazard Analysis implementation. It establishes a practical roadmap for ongoing safety improvements that align with organizational goals.

Risk Reduction Through systematic evaluation, facilities decrease the likelihood of safety incidents and minimize exposure to hazards. The assessment leads to better process control and emergency response preparation, creating a safer work environment.

Documentation and Compliance

Our assessment process generates comprehensive documentation that supports your ongoing safety programs and regulatory requirements.

Documentation Elements:

  • Detailed site assessment findings
  • Material safety data and test results
  • Process flow diagrams with hazard indicators
  • Risk assessment matrices
  • Employee interview summaries
  • Equipment evaluation reports
  • Recommended control measures
  • Compliance gap analysis
  • Implementation priority list

 Compliance Support Features:

  • Alignment with current industry standards
  • Integration with existing safety programs
  • Clear tracking of regulatory requirements
  • Documentation for insurance purposes
  • Employee training records
  • Maintenance procedure recommendations
  • Emergency response planning guidance
  • Periodic review schedules
  • Update protocols for changing conditions

The Sigma-HSE Advantage

We bring decades of plant experience and deep knowledge of industry standards to every safety assessment. Our team’s expertise spans across complex industrial operations, allowing us to develop targeted solutions that address your specific needs. For operations involving flammable or highly hazardous chemicals, we conduct detailed Process Hazard Analysis to identify and mitigate risks effectively.

In facilities managing combustible dust risks, our specialized Dust Hazard Analysis provides comprehensive evaluation and practical safety recommendations. This dual capability ensures that regardless of your facility’s specific challenges, you receive focused, industry-appropriate guidance. Our approach combines practical solutions with technical excellence, delivering results that enhance operational safety while maintaining productivity.

Contact us today to schedule your safety assessment and take the first step toward enhancing your facility’s safety profile. Our experienced team is ready to help you build a stronger safety foundation for your operations.

Request a Preliminary Hazard Assessment Quote

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Frequently asked questions

If you’re introducing a new process to your facility that involves flammable liquids/vapors, highly hazardous chemicals, or a material capable of generating dust, the potential risk of the new process should be evaluated to ensure that the proper precautions are taken to prevent an incident from occurring.

Depending on the results of the Preliminary Hazard Assessment, it may be appropriate to perform a Process Hazard Assessment for flammables or highly hazardous chemicals or a Dust Hazard Analysis for combustible dust concerns. If the Preliminary Hazard Assessment demonstrates no further action is required, it can be used as evidence of due diligence performed to evaluate potential risks for your facility.

Whether dealing with bulk storage of chemicals of concern or lab quantities, there is always a risk involved. A Preliminary Hazard Assessment will help you identify the base risk and ensure you take the proper precautions to avoid incidents.

What Our Customers Say

The detail oriented approach of the consultants helped our team in identifying the various risks & hazards involved in different stages of the project and helped us in making design and operational changes at the right time.
Project Engineer
Chemicals Industry
I would like to highlight the prompt and professional response to our enquiry, the quick turnaround time for the tests and report, and the constant communication throughout the process.
Senior Process Development Engineer
Electronics Parts Supplier
I just want to extend my compliments to your technical team for their valuable contributions to the HAZOP. Their feedback was excellent, and the facilitation was outstanding.
Principal Mechanical Engineer
Large Aluminum Manufacturer
Sigma-HSE completed DSEAR assessments for multiple sites around the UK with flawless execution. Considering our flammable chemical inventories, the assessments were crucial in identifying hazardous areas to reduce the risks of explosive atmospheres at our sites.
Site Head of Engineering
Printing Industry

Blog

NFPA 652
Guidelines for Managing Combustible Dust

Process Hazrad

Blog

What is Process Hazard Analysis and its Comparative Study of Methodologies

sparksheet-1

Sparksheet

Is My Dust Combustible?

Video

Minimum Ignition Test

 

 

If you find yourself asking, ‘Do I need a Preliminary Hazard Assessment at my facility?’, connect with us today. One of our subject matter experts will guide you through any questions you may have.

Starting Safely with Preliminary Hazard Assessment for Complex Facilities

The preliminary hazard assessment is an important aspect in keeping people, the environment, and business safe from risks relating to fire and explosions. Learn more about how we can assist you today 

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