Consulting Services

Quantitative Risk Assessments (QRA) (MHI Risk Assessment)

We help you quantify the risks of fires, explosions, and toxic releases—giving you the insight needed to make safety investments with confidence.

What We Do:

Identify potential hazards using HAZID or HAZOP results
Estimate event frequencies using failure data (e.g., OREDA)
Model consequences with industry software like PHAST or Gexcon
Calculate and visualize risk (e.g., FN curves, risk contours)
Recommend targeted mitigation measures or ALARP justifications

Standards We Follow:
CCPS RBPS Guidelines, UK HSE R2P2, API 754, SANS 1461

Hazardous Area Classification (HAC)

We classify areas where explosive atmospheres may form, helping ensure compliant and safe equipment selection in line with ATEX and IEC standards.

Our Approach:

Review flammable material properties and release potential
Assess ventilation to determine gas cloud behaviour
Assign gas (Zone 0/1/2) or dust (Zone 20/21/22) zones
Prepare detailed area classification drawings and equipment specs

Standards We Use:
IEC 60079-10, ATEX 2014/34/EU, NFPA 497/499, SANS 10108

Fire & Explosion Risk Assessments (FERA)

We evaluate fire and explosion risks at your facility and recommend mitigation strategies that reduce escalation potential.

Our Scope Includes:

Developing credible scenarios (jet fire, flash fire, VCE)
Assessing ignition sources and likelihood
Modeling thermal radiation and blast overpressure
Ranking risks and identifying protective measures (e.g., fireproofing, spacing)

Standards Applied:
API 521, NFPA 68 & 69, BS EN 14491

Fire & Gas Detection Layouts

We design optimized layouts for fire and gas detectors, ensuring early hazard detection and

How We Help (continued):

Select the right detector types (flame, point, open-path)
Use advanced 3D modeling tools (e.g., Flacs to optimize placement
Design for redundancy and coverage reliability
Integrate testing and maintenance strategies to ensure system uptime

Standards Followed:
ISA TR84.00.07, NFPA 72, IEC 61511

Process Safety Audits

We conduct independent, thorough audits to evaluate the effectiveness of your Process Safety Management System (PSMS) and identify areas for improvement.

Audit Scope:

Review key documents: P&IDs, procedures, safety reports
Interview personnel and conduct site walkdowns
Test critical systems (e.g., permit-to-work, SIS, alarm management)
Benchmark against OSHA PSM, ISO 45001, and CCPS frameworks
Deliver clear, risk-prioritized action plans

Standards Referenced:
OSHA 1910.119, ISO 45001, CCPS RBPS

HAZOP (Hazard and Operability) Studies

A HAZOP (Hazard and Operability) study is a structured and systematic technique for examining potential hazards and operability problems in a process system. It is typically applied to complex systems such as chemical plants, oil & gas facilities, and other high-risk industrial operations.

The study is qualitative in nature and is conducted by a multidisciplinary team using a guided brainstorming approach to identify deviations from design intent that could lead to hazardous situations or operational issues.

We facilitate structured HAZOP workshops to identify potential process deviations and ensure robust safeguards are in place.

Our Method:

Divide systems into logical “nodes” using P&IDs
Apply guidewords like “No flow,” “High pressure,” or “Reverse”
Identify causes, consequences, and existing protections
Recommend improvements to design, procedures, or instrumentation

Standards Used:
IEC 61882, CCPS Hazard Evaluation Guidelines

Safety Instrumented Systems (SIS)

We help design and verify SIS to ensure they perform their intended safety functions—such as triggering shutdowns in case of abnormal conditions.

Our Services Include:

Determining Safety Integrity Level (SIL) using LOPA or risk matrices
Developing Safety Requirements Specifications (SRS)
Designing SIS components: sensors, logic solvers, final elements
Conducting SIL verification and defining proof test intervals
Managing the full SIS lifecycle for long-term reliability

Standards Followed:
IEC 61511, IEC 61508, ISA S84

LOPA (Layer of Protection Analysis) Study

LOPA is a semi-quantitative risk assessment method used to evaluate whether existing or proposed independent protection layers (IPLs) are adequate to reduce the risk of hazardous events to acceptable levels. It bridges the gap between qualitative methods (like HAZOP) and quantitative risk assessments (like QRA).

Objectives of LOPA

Identify hazardous scenarios
Estimate the frequency and consequences of each scenario
Determine if existing safeguards are sufficient
Evaluate the need for additional protection layers (e.g., Safety Instrumented Functions – SIFs)
Assign Safety Integrity Levels (SIL) to SIFs

Standards Followed

IEC 61511 – Functional Safety for the Process Industry Sector
IEC 61508 – Functional Safety of Electrical/Electronic/Programmable Safety-Related Systems
CCPS LOPA Book – Layer of Protection Analysis: Simplified Process Risk Assessment (AIChE/CCPS)
ISA TR84.00.02 – Guidelines for LOPA

RAM (Reliability, Availability, Maintainability) Studies

Purpose

RAM studies assess the system’s ability to perform its intended function over time. They help optimize design for reliability, ensure operational efficiency, and inform decisions regarding maintenance and spare parts strategy.

Key Components

System Description
- Functional overview
- Block diagrams (Reliability Block Diagram – RBD or functional diagrams)
- System boundaries and assumptions
Data Collection
- Failure and repair data (MTBF, MTTR)
- Manufacturer reliability data, historical field data, or industry databases (e.g., OREDA, IEEE Gold Book)
Model Development
- Reliability Block Diagrams (RBD)
- Fault Tree Analysis (FTA)
- Event Tree Analysis (ETA)
- Markov Models or Monte Carlo simulations (for complex systems)
Analysis Metrics
- Reliability (R) – probability of no failure in time t
- Availability (A) – proportion of time system is operational
- Maintainability (M) – ease and speed of repair
- MTBF – Mean Time Between Failures
- MTTR – Mean Time To Repair
- System Downtime estimates
- Spare part optimization
Sensitivity Analysis
- Impact of failure rate variation
- Redundancy optimization
- Critical component identification
Results & Recommendations
- RAM KPIs summary
- Recommendations for design improvements
- Maintenance strategy suggestions
- Spare parts and logistics planning

Applicable Standards

IEC 61078 – Reliability Block Diagrams
IEC 61703 – Mathematical expressions for reliability, availability, maintainability
IEC 60300 series – Dependability management
ISO 14224 – Collection and exchange of reliability and maintenance data
IEEE 3006.7 – Reliability modeling and evaluation of electrical systems

FMEA (Failure Modes and Effects Analysis)

Purpose

FMEA identifies potential failure modes within a system, their causes and effects, and prioritizes them to mitigate risk and enhance design or operational reliability.

Types of FMEA

Design FMEA (DFMEA) – Applied during product or system design
Process FMEA (PFMEA) – Applied during manufacturing or process planning
System FMEA – Evaluates failure impacts at system-level

Key Components

System Breakdown
- Define system, sub-systems, and components
- Identify interfaces and boundaries
Failure Mode Identification
- Potential ways a component may fail
Effects of Failure
- Local, system-wide, and end-user impacts
Causes of Failure
- Root cause analysis (RCA), 5 Whys, or Ishikawa diagram
Detection & Controls
- Existing design/process controls that prevent or detect the failure
Risk Assessment
- RPN (Risk Priority Number) = Severity × Occurrence × Detection
- Alternatives: Action Priority (AP) rating (as per AIAG-VDA)
Recommended Actions
- Design changes, maintenance strategy, operational controls
Follow-Up
- Track mitigation actions
- Recalculate RPN or AP after improvements

Applicable Standards

IEC 60812:2018 – Analysis techniques for system reliability – FMEA
AIAG-VDA FMEA Handbook (2019) – Automotive industry FMEA best practices
MIL-STD-1629A – Procedures for performing FMECA (military standard)
SAE J1739 – Guidelines for automotive FMEA
ISO 14971 – Risk management for medical devices

Deliverables in Both Studies

Executive summary
Methodology and assumptions
Input data and sources
Detailed analysis (RAM model/FMEA worksheet)
Sensitivity analysis (RAM)
Risk prioritization table (FMEA)
Recommendations
Appendices (supporting calculations, reliability data, diagrams)

Combustible Dust Risk Assessment (CDRA) – Service Description

Overview

A Combustible Dust Risk Assessment (CDRA) is a systematic evaluation of the potential for combustible dust-related fires and explosions in industrial facilities. It identifies hazardous dust accumulation points, evaluates ignition sources, and determines the adequacy of existing protection measures, in accordance with national and international safety standards.

This service helps facilities comply with regulatory requirements, prevent catastrophic incidents, and implement cost-effective risk mitigation strategies.

Objectives of the CDRA

Identify areas where combustible dust hazards exist
Determine the explosibility and combustibility characteristics of dust
Evaluate process conditions and equipment that could lead to deflagration or explosion
Recommend engineering and administrative controls to reduce risk
Ensure compliance with applicable codes and standards

Applicable Standards and Regulations

NFPA 652 – Standard on the Fundamentals of Combustible Dust
NFPA 61, 654, 484, 655, 664 – Industry-specific combustible dust standards
OSHA 29 CFR 1910 Subpart Z – Hazardous Substances and PSM guidelines
OSHA CPL 03-00-008 – National Emphasis Program (NEP) for Combustible Dust
ATEX 137 / Directive 1999/92/EC – EU requirements for explosive atmospheres
ISO/IEC 80079-20-2 – Combustible dust properties for classification

When Is a CDRA Required?

During design or modification of facilities handling dust
For compliance with NFPA 652, which requires a Dust Hazard Analysis (DHA)
After a process change, incident, or new material introduction
As part of a Process Hazard Analysis (PHA) program

Team Composition

Process Safety Consultant (Lead Assessor)
Plant/Process Engineer
Maintenance & Operations Personnel
Electrical Engineer (for ignition source review)
Industrial Hygienist or Dust Testing Specialist (optional)

Key Elements of the CDRA

Material and Process Review

Inventory of dust-producing materials
Review of MSDS/SDS for explosibility indicators
Sample collection for lab testing(optional) (Kst, Pmax, MIE, MEC, MIT)
Review of process equipment: dryers, mixers, hoppers, conveyors

Facility Walkthrough

Inspection of dust accumulation locations
Identification of dispersion and containment weaknesses
Evaluation of ventilation and housekeeping practices

Ignition Source Analysis

Mechanical sparks, static electricity, hot surfaces
Electrical classification of equipment
Welding/hot work procedures

Dust Explosion Pentagon Analysis

Evaluate the five key elements:

Fuel (combustible dust)
Dispersion (airborne cloud)
Oxidizer (air)
Confinement (building, duct, vessel)
Ignition source

Dust Hazard Analysis (DHA)

Identification of credible deflagration/explosion scenarios
Assessment of likelihood and consequences
Evaluation of existing safeguards:
- Deflagration venting
- Suppression systems
- Isolation valves
- Inerting systems
- Housekeeping programs

Risk Evaluation and Ranking

Risk matrix or semi-quantitative scoring (likelihood × severity)
Gap analysis against applicable standards

Recommendations and Mitigation Measures

Engineering Controls: spark detection, venting, isolation
Administrative Controls: SOPs, maintenance, housekeeping
Electrical upgrades per NFPA 70 (NEC)
Dust testing and monitoring plans

CDRA Deliverables

Combustible Dust Risk Assessment Report
- Executive summary
- Description of materials, process, and facility layout
- Dust test data summary (optional) (Kst, Pmax, MIE, etc.)
- Hazard scenarios and risk evaluation
- Existing safeguards and their adequacy
- Gap analysis and compliance review
- Actionable recommendations
Dust Hazard Analysis (DHA) Table
Node-by-node or process-by-process documentation of hazards and controls.
Explosion Protection Map or Layout (optional)
Annotated layout showing hazardous areas and protection systems.
Compliance Checklist
Checklist based on NFPA 652 and applicable industry-specific standards.
Implementation Roadmap
Prioritized action items with suggested timelines and responsibility assignments.

Human Factors Assessment in Industrial Applications

Overview

At MHI Risk Engineers, we understand that human reliability is a critical component of overall process safety. Our Human Factors Assessment (HFA) services are designed to systematically evaluate how humans interact with industrial systems—ensuring that the design, procedures, and organizational structures support safe, efficient, and error-free operations.

What Are Human Factors?

Human factors refer to the environmental, organizational, job, and individual characteristics that influence behavior at work in a way that can affect health, safety, and performance. This includes:
• Human-machine interaction
• Fatigue and workload management
• Situational awareness
• Communication and teamwork
• Control room ergonomics
• Training and competence
• Procedures and operational discipline

Failures in these areas often contribute to major accidents, including those seen in high-hazard industries like oil and gas, chemicals, mining, and power generation.

Why Human Factors Matter in Process Safety

Human error contributes to a significant proportion of industrial incidents. However, most errors are system-induced and predictable. Through proper assessment and design, we can engineer out errors and build resilience into operations.

Our Human Factors Assessment Approach

We apply a systematic, risk-based methodology aligned with best international practices. Our process typically includes:
1. Task Analysis
Identify and assess safety-critical tasks and human error potential.
2. Interface Design Review
Evaluate control rooms, HMIs, alarms, and physical workspace layout.
3. Organizational and Procedural Review
Assess shift handover, permit-to-work systems, fatigue management, and competency.
4. Human Reliability Analysis (HRA)
Use structured techniques like THERP, HEART, or SPAR-H to estimate error likelihoods.
5. Recommendations & Integration
Develop practical mitigation measures integrated into existing safety management systems (SMS).

Applicable Human Factors Standards and Guidance

We align our assessments with globally recognized standards and guidelines, including:

United Kingdom
• HSE Human Factors Roadmap – Health and Safety Executive (UK)
• Reducing Error and Influencing Behaviour (HSG48) – HSE
• OGUK Guidelines for Human Factors Integration – Offshore UK
• Energy Institute Human Factors Framework

United States
• ANSI/ISA 101.01 – Human-Machine Interface Design
• API RP 770 – Control Room Management
• CCPS Guidelines for Preventing Human Error in Process Safety – AIChE
• NRC Human Factors Engineering Program Review Model

Industries We Serve
• Oil & Gas (onshore & offshore)
• Petrochemical & Chemical Processing
• Power Generation
• Mining & Metals
• Food & Beverage Manufacturing
• Pharmaceutical and Biotech

Why Choose MHI Risk Engineers?

With a deep understanding of both technical systems and human behavior, we bring a balanced, evidence-based approach to human factors assessments. We don’t just audit—we collaborate with your teams to build safer, smarter, and more resilient operations.

Let’s put people at the center of safety.
Contact us today to learn how we can support your plant or project with a tailored human factors solution.

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