A strong Process Safety Management (PSM) system is essential for preventing incidents, achieving compliance, and safeguarding people, assets, and operations in any facility handling highly hazardous chemicals. Sigma-HSE specializes in advanced risk and hazard assessments at the core of PSM, supported by a suite of consulting services that address every critical aspect of process safety.
Whether you need a comprehensive gap analysis, a targeted PHA, or support following an incident, we provide the technical insight and regulatory confidence required for safer, more resilient operations.
Comprehensive Compliance: Ensure your facility meets OSHA PSM 29 CFR 1910.119 requirements and industry best practices, reducing the risk of regulatory penalties and shutdowns.
Operational Safety & Reliability: Identify and control hazards to prevent incidents, minimize downtime, and protect your workforce, assets, and reputation.
Actionable, Practical Results: Receive clear, prioritized recommendations and practical roadmaps for improving process safety, not just checklists or generic reports.
Deep Industry Experience: Leverage Sigma-HSE’s extensive experience across chemical, petrochemical, pharmaceutical, energy, water treatment, and other high-hazard industries.
Independent Expertise: Gain objective insights and best-in-class support from a trusted, specialized process safety partner.
With extensive cross-industry expertise and a track record of delivering measurable results, Sigma-HSE brings strategic insight and technical excellence to every engagement. Our consultants help you navigate regulatory complexities, reduce operational risk, and elevate safety performance across your organization.
Specialized Expertise: Our team brings decades of hands-on experience in process safety management, risk assessment, and compliance across chemical, petrochemical, pharmaceutical, energy, and manufacturing sectors.
Trusted, Data-Driven Insight: We provide data-driven analysis and tailored recommendations specific to your facility—ensuring every solution is actionable, relevant, and grounded in proven industry experience.
Comprehensive, Integrated Approach: From detailed hazard analysis and gap assessments to incident investigation and management system support, we offer end-to-end services that strengthen your PSM program at every stage.
Commitment to Safety: Our work helps reduce the likelihood of incidents, improve compliance, lower operational costs, and protect your people, assets, and reputation-delivering measurable business and safety benefits.
Our team delivers in-depth Process Hazard Analyses (PHA) using industry-leading and integrated methodologies to systematically identify, evaluate, and prioritize process risks. We quantify potential impacts and ensure risk is reduced to acceptable levels, providing actionable insights for effective decision-making. All assessments are conducted by experienced consultants and fully align with OSHA PSM 29 CFR 1910.119 requirements.
Process Hazard Analysis (PHA): HAZOP, HAZOP/LOPA, What-If, Checklist, and combined methodologies to systematically identify and evaluate process risks.
Hazard Identification (HAZID): High-level, workshop-based qualitative risk identification applicable at any project stage.
Quantitative Risk Assessment (QRA): Quantifying potential impacts and likelihoods.
ALARP (As Low As Reasonably Practicable) Studies: Ensuring risk is reduced to acceptable, practical levels.
Consequence Modeling: Predicting and visualizing the potential effects of hazardous events.
Beyond risk and hazard assessments, Sigma-HSE offers a comprehensive suite of process safety management consulting services to support every stage of your facility’s safety journey. Our experienced consultants partner directly with your team to address gaps, enhance in-house capabilities, and ensure your safety management systems are resilient. These services are designed to help organizations build resilience, foster a strong safety culture, and maintain operational excellence in line with OSHA PSM (29 CFR 1910.119) and industry best practices.
Hazardous Area Classification (HAC) – Identify and define Class I hazardous (flammable gas or vapor) locations in accordance with NFPA 497, ensuring proper electrical equipment selection and reducing ignition risk in PSM-covered operations.
PSM Gap Analysis: A systematic review of your current PSM program to pinpoint discrepancies, deficiencies, and opportunities for improvement. Our gap analysis aligns with OSHA PSM (29 CFR 1910.119) and CCPS Guidelines, providing a clear roadmap for compliance and enhanced safety.
Incident Investigation & Root Cause Analysis: Thorough, systematic investigation of incidents and near-misses to uncover underlying causes and develop effective corrective actions.
Process Safety Training: Building in-house capability to lead and sustain process safety initiatives.
Safety Management System Design and Integration: Enhancing or aligning your existing management systems with PSM best practices and regulatory requirements.
Pre-Startup Safety Review (PSSR) & Shutdown Support: Ensuring safety-critical systems are rigorously evaluated before commissioning or during shutdowns.
Sigma-HSE’s experienced consultants partner directly with your team to deliver tailored, cost-effective solutions that address your facility’s unique risks and operational realities.
While Sigma-HSE’s core process safety management consulting services are grounded in OSHA PSM (29 CFR 1910.119) and U.S. regulatory requirements, our team also brings extensive experience with leading international standards and directives.
We support clients operating globally, or those seeking to align with best practices beyond U.S. borders, by integrating:
Seveso III Directives (EU): Guidance and compliance support for facilities subject to the EU’s Seveso III Directive, including major accident prevention policies, safety reporting, and emergency planning.
COMAH Regulations (UK): Consulting for UK sites to meet the Control of Major Accident Hazards (COMAH) Regulations, covering hazard identification, risk assessment, and safety management system alignment.
Emergency Relief Sizing: Technical expertise in emergency relief system design and validation, including vent sizing and consequence modeling, in accordance with global standards such as API 520/521 and relevant international guidelines.
Our ability to apply both U.S. and international process safety frameworks ensures that your organization remains compliant, resilient, and prepared-no matter where you operate. Sigma-HSE is your trusted partner for process safety management, offering a global perspective with local expertise.
The primary goal of process safety management is to use process safety information to create systems and practices for plants in order to prevent unintended fires, explosions or toxic releases, that could impact business, people, the workplace and the environment.
A thorough process safety policy should create and regulate the key principles that govern a sustainable business. An organisation should clearly set its regulatory safety standards, risk management strategies and legal compliance while covering hazard identification and other risk assessments.
There is an emphasis on process safety for the management of hazards associated with highly hazardous chemicals. A comprehensive management program will therefore integrate technology, procedures, and management practices to ensure safety risks are controlled.
Additionally, these purpose built process safety management programmes will address problems with operational viability, productivity, stability, and product quality.
Managing process safety requires the implementation of effective management and leadership strategies. This requires everyone in your business from the CEO, the board, senior leaders and operators all committing and embracing a dedicated culture.
As new attitudes towards process safety leadership emerge, leaders must now inject themselves into the extremely technical, scientifically complex and high-risk based field, the processing industry.
Leaders must also further commit themselves to the day-to-day activities of the process safety leadership and operational teams, make positive performance suggestions and understand the variety of health and safety legislation available.
Multiple techniques are used to ensure organisations meet safety management systems and/or national and international legislative requirements. Building and integrating a custom system or framework will help manage safety in the workplace.
These highly organised, corporate-wide procedures facilitate efficient risk-based decision-making for operational tasks. Our consultants provide a bespoke platform for you to incorporate purpose built safety management systems for your operations, so you can ensure regulatory compliance and drive product performance.
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Process safety management enables your safety management systems to run effectively whilst meeting legislative and safety regulator requirements. Learn more about how we can assist you today.
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