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OSHA & NFPA Compliance Solutions

Sigma-HSE provides comprehensive Process Safety Management (PSM) and NFPA compliance solutions to help industries identify hazards, manage risks, and meet regulatory standards for safe operations. Our consultants specialize in both OSHA 29 CFR 1910.119 compliance for highly hazardous chemicals and NFPA 660 compliance for combustible dust hazards.

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Let our experts create a tailored compliance solution for your facility.

Comprehensive Compliance Solutions

Why Choose Sigma-HSE?

Our team delivers:

Comprehensive expertise in both OSHA PSM and NFPA compliance
Fast, reliable testing with industry-leading turnaround times
Customized solutions tailored to your facility’s unique risks
Experienced consultants who specialize in fire, explosion, and chemical hazard prevention

Get Your Customized Compliance Plan

Let our experts help you navigate complex regulations with tailored compliance solutions for your facility. Contact us today to develop a comprehensive plan that aligns with both OSHA and NFPA requirements.

Why NFPA and OSHA Compliance Matters

Did you know OSHA compliance has reduced workplace fatalities by 60 percent? *

Fire, explosion, and other hazards pose serious risks in industrial operations, particularly in facilities handling combustible dust, flammable materials, and hazardous chemicals. Implementing NFPA and OSHA standards helps businesses:

Enhance workplace safety & reduce risks
Avoid costly penalties & meet regulatory requirements.
Protect valuable assets & ensure business continuity
Lower insurance premiums & minimize legal liabilities

The Compliance Imperative: Between 2013 and 2017, OSHA conducted 2,553 combustible dust inspections, identifying 3,389 violations — highlighting the need for expert guidance as compliance gaps remain a common challenge for industrial facilities.*

By focusing on the importance of proactive compliance instead of the threat of violations, we encourage engagement and demonstrate that we’re here to help them identify gaps and protect their people and facilities.

Comprehensive Compliance & Risk Mitigation Solutions

Our tailored compliance services combine in-depth hazard identification with specialized testing and risk mitigation strategies to ensure facilities achieve full OSHA and NFPA compliance.

OSHA Process Safety Management (PSM) 29 CFR 1910.119 Compliance

Our consultants help facilities implement effective PSM programs that prevent fires, explosions, and toxic releases in hazardous environments.

Customized risk assessment & mitigation for chemical process safety including:
- Process Hazard Analysis (PHA) using proven methodologies such as:
  - HAZOP (Hazard and Operability Study)
  - HAZID (Hazard Identification)
  - LOPA (Layers of Protection Analysis)
PSM Gap Analysis and Compliance Audits to identify regulatory gaps and improvement opportunities
Pre-Startup Safety Reviews (PSSR) to ensure system readiness before operations
Incident Investigation to identify root causes, implement corrective actions, and prevent recurrence
Development of comprehensive PSM programs that align with OSHA standards
Electrical area classification and ignition source control

NFPA 660 Combustible Dust Compliance

Facilities handling combustible and/or explosible dust must comply with NFPA 660 to mitigate fire and explosion hazards. Our consultants provide expert guidance to help facilities reduce their risk.

Tailored risk assessment & mitigation solutions to identify and mitigate dust fire, flash-fire, and explosion risks through:
- Dust Hazard Analysis (DHA) to evaluate dust explosibility, ignition sources, and fire hazards, using two proven approaches:
  - Traditional (Prescriptive) – Utilizes expert knowledge and experience related to solids-handling operations while adhering to relevant standards.
  - Risk-Based (Performance) – Evaluates risk based on potential consequences and the likelihood of occurrence over a defined timeframe, often involving team meetings with key personnel to gather operational insights, assess site-specific risks, and develop practical mitigation strategies.
NFPA Gap Analysis and Compliance Audits to identify gaps in combustible dust safety programs and recommend improvements.
Development of combustible dust management programs that align with NFPA 660 standards.
Hazardous Area Classification (NFPA 499 & NEC Standards) to identify hazardous locations, develop NFPA-classified area maps, and ensure compliance with OSHA, NFPA 499, and NEC standards.
Incident Investigation to identify root causes, implement corrective actions, and prevent recurrence.

Combustible Dust, Flammable Gas/Vapor & Chemical Reaction Hazard Testing

Our specialized testing services provide accurate, reliable data for risk assessment and hazard mitigation across a range of industries. We deliver fast, reliable results to support both OSHA PSM and NFPA compliance:

OSHA Process Safety Management (PSM) standard (29 CFR 1910.119)
NFPA 660 (Combustible Dust Standard)
NFPA 30 Flammable and Combustible Liquids
NFPA 68/69 (Explosion Protection Standards)
NEC Article 500/502 (Hazardous Area Classification)

Our accredited laboratory offers fast, reliable results in 7-10 business days for:

Combustible Dust Testing

Explosibility Screening (Go / No Go Testing)
Combustibility Screening (Burning Behavior)
Minimum Ignition Energy (MIE)
Minimum Ignition Temperature Cloud (MIT Cloud)
Minimum Ignition Temperature Layer (MIT Layer)
Explosion Severity (KSt Pmax, dP/dtmax,)
Minimum Explosive Concentration (MEC)
Limiting Oxygen Concentration (LOC)

Flammable Gas & Vapor Testing

Lower Explosive Limit (LEL) and Upper Explosive Limit (UEL)
Flammable Range Determination
Autoignition Temperature (AIT)

Chemical Reaction Hazard Testing

Accelerating Rate Calorimetry (ARC)
Differential Scanning Calorimetry (DSC)
Reaction Screening Tool (RSST)
Vent Sizing Package (VSP2) for runaway reaction assessment

Combustible Dust Testing

Explosibility Screening (Go / No Go Testing)
Combustibility Screening (Burning Behavior)
Minimum Ignition Energy (MIE)
Minimum Ignition Temperature Cloud (MIT Cloud)
Minimum Ignition Temperature Layer (MIT Layer)
Explosion Severity (KSt Pmax, dP/dtmax,)
Minimum Explosive Concentration (MEC)
Limiting Oxygen Concentration (LOC)

Flammable Gas & Vapor Testing

Lower Explosive Limit (LEL) and Upper Explosive Limit (UEL)
Flammable Range Determination
Autoignition Temperature (AIT)

Chemical Reaction Hazard Testing

Accelerating Rate Calorimetry (ARC)
Differential Scanning Calorimetry (DSC)
Reaction Screening Tool (RSST)
Vent Sizing Package (VSP2) for runaway reaction assessment

Why Choose Sigma-HSE?

Our team delivers:

Comprehensive expertise in both OSHA PSM and NFPA compliance
Fast, reliable testing with industry-leading turnaround times
Customized solutions tailored to your facility’s unique risks
Experienced consultants who specialize in fire, explosion, and chemical hazard prevention

Get Your Customized Compliance Plan

Let our experts help you navigate complex regulations with tailored compliance solutions for your facility. Contact us today to develop a comprehensive plan that aligns with both OSHA and NFPA requirements.

Industry-Specific Compliance Standards

In today’s complex industrial landscape, adherence to process safety standards is crucial for protecting workers, assets, and the environment. This guide outlines key industry-specific compliance requirements and relevant safety standards from the National Fire Protection Association (NFPA) and the Occupational Safety and Health Administration (OSHA).

Industry-Specific Compliance

Our consultants specialize in hazard identification and mitigation for various industries, ensuring adherence to both NFPA and OSHA standards:

Manufacturing & Processing Plants
Food & Agricultural Facilities (Grain, Sugar, Flour Processing, etc.)
Wood & Paper Industries (Sawmills, Pulp, and Woodworking Facilities)
Metalworking Facilities (Aluminum, Magnesium, Titanium Processing)
Chemical & Pharmaceutical Facilities (Chemical Reactors, Solvent Processing)
Oil & Gas, Energy, and Petrochemical Plants (Refineries, LNG Storage, etc.)

NFPA Standards for Combustible Dust & Process Safety

Our team helps facilities meet key NFPA standards, including:

NFPA 660 – Unified Combustible Dust Standard

Combines NFPA 61, 484, 652, 654, 655, and 664 into a single framework for simplified hazard management.
Introducing Proactive solutions that anticipate regulatory changes
Delivers a streamlined approach to multi-industry compliance

NFPA 652 – Dust Hazard Analysis (DHA) & Combustible Dust Fundamentals

Defines requirements for risk assessment and management across all combustible dust types.
Establishes a detailed DHA methodology
Examines ignition sources and dust accumulation risks

NFPA 654 – Prevention of Fire & Dust Explosions

Provides standards for manufacturing facilities handling combustible particulate solids.
Evaluates fire propagation and secondary explosion risks
Develops ventilation and suppression system design

NFPA 33 – Spray Application Using Flammable & Combustible Materials

Outlines fire and explosion protection for spray applications using flammable materials.
Specifies ventilation and static control requirements
Specifies fire-rated enclosures and suppression system designs

NFPA 61 – Agricultural & Food Processing Dust Hazards

Establishes fire prevention standards for facilities handling combustible dust in agricultural environments.
Includes explosion hazard assessments and dust control strategies
Identifies dust collection and material handling system requirements

NFPA 484 – Combustible Metals & Metal Dust Handling

Regulates facilities handling aluminum, magnesium, titanium, and other reactive metals
Implements Specialized dust collection & containment systems
Defines Safe handling procedures for reactive metals

NFPA 664 – Wood Processing & Combustible Wood Dust Safety

Establishes safety measures for woodworking and sawmill operations
Addresses dust accumulation and ventilation requirements
Guides the development of dust mitigation programs

OSHA Process Safety Management (PSM) 29 CFR 1910.119

The Occupational Safety and Health Administration (OSHA) developed the Process Safety Management (PSM) standard to prevent or minimize the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals.

The 14 Elements of PSM

OSHA’s PSM standard outlines 14 key elements that covered facilities must implement to ensure process safety:

Employee Participation: Encourage and require employee involvement in PSM-related initiatives.
Process Safety Information: Compile and maintain written documentation on process hazards, technology, and equipment.
Process Hazard Analysis: Conduct and regularly update comprehensive hazard assessments for covered processes.
Operating Procedures: Develop and implement clear, written procedures for safely conducting activities in each covered process.
Training: Provide initial and refresher safety training to employees, emphasizing process-specific hazards and safe work practices.
Contractors: Implement proper safety measures for contract workers involved in covered processes.
Pre-Startup Safety Review: Conduct safety reviews before introducing new processes or restarting modified ones.
Mechanical Integrity: Verify proper design, installation, and maintenance of critical process equipment.
Hot Work Permit: Implement a permit system for hot work activities conducted near covered processes.
Management of Change: Establish procedures for managing changes in processes, equipment, or personnel changes.
Incident Investigation: Investigate and document all incidents involving or potentially involving HHC releases.
Emergency Planning and Response: Develop plans for handling potential chemical releases and emergencies.
Compliance Audits: Conduct and document compliance audits at least every three years.
Trade Secrets: Maintain proper handling of confidential information while maintaining safety standards.

NFPA & OSHA: A Complementary Approach

While NFPA standards focus on specific hazards and industries, OSHA’s PSM standard provides a comprehensive framework for managing process safety. Together, these standards create a robust safety management system that addresses both general and industry-specific risks.

Navigating the complex landscape of industry-specific compliance and safety standards requires expertise and dedication. Our team of consultants is ready to help your facility implement these crucial safety measures, ensuring compliance with both NFPA and OSHA requirements while creating a safer work environment.

Get Your Customized Plan