Consultivo · Process Safety · IFC-Approved
Process Safety Management Consultants for High-Hazard Plants
Independent process safety studies that prevent the big events - fire, explosion and toxic release. PHA, HAZOP, QRA, HIRA and hazardous area classification, facilitated by consultants who sell no equipment and no software.
What You Get
Process Safety Studies We Deliver
Five core studies plus two focused add-ons, each run as an independent facilitation and delivered as a scored, management-ready report you can act on the same week.
Process Hazard Analysis
A family of structured studies - HAZID, What-If and Checklist - that surface the major hazard categories before drawings are frozen. Facilitated by our process hazard analysis consultants.
HAZOP Study
A guide-word review of your P&IDs to find hazardous deviations and operability gaps. Led by experienced hazop consultants who facilitate rather than just attend.
Quantitative Risk Assessment
Consequence modelling, risk contours and F-N curves for siting, PNGRB and lender needs. Delivered by a QRA consultant team with modelling depth.
Hazardous Area Classification
Zone drawings that define where flammable atmospheres may occur and what equipment is safe there. Our hazardous area classification work aligns to PESO.
HIRA, Process Focus
A risk register that goes past routine task hazards into reactivity, failure modes and control-room error. Built through structured hazard identification and risk assessment.
PSM Audit
An independent review of your management systems and technical safeguards against the 14 PSM elements and site practice, with a scored gap register.
LOPA & SIL Determination
Where a HAZOP flags a scenario needing an engineered safeguard, we extend it with Layer of Protection Analysis and set the target safety integrity level.
Why Consultivo
A Process Safety Partner That Goes Beyond Compliance
Independence, sector depth and outputs you can act on - not a box-ticking file.
IFC World Bank Group approved
The independence and technical rigour that development lenders and international insurers expect for project-financed, high-hazard facilities.
Truly independent
We sell no equipment, no software licences and no instrumentation. Our only product is an unbiased assessment, which is the quality that matters most.
Scored risk register and dashboard
Every study lands as a scored register with heat maps and charts, so leadership can see priority, owner and timeline at a glance.
Multi-standard fluency
IEC 61882, IEC 60079, IS 5572, OSHA PSM, IFC PS3, ISO 31000 - we work to the standard your regulator or lender actually expects.
India and 19+ countries
Indian statutory depth (PESO, PNGRB, Factories Act) combined with IEC, ISO and IFC practice, credible in one place.
AA1000 assurance provider
A licensed assurance provider with credentials across chemicals, oil and gas, pharma and manufacturing, and 2,000+ organisations served.
Understanding The Discipline
What Is Process Safety Management?
Process safety management is the systematic framework for preventing the unplanned release of hazardous material or energy from process equipment. It targets the low-frequency, high-severity events - fires, explosions and toxic releases - that routine occupational safety does not address.
In oil and gas, chemicals, pharmaceuticals and petrochemicals, the risk is not only slips and manual handling. It is flammable gas, toxic vapour, runaway reactions and pressure systems, where a single failure can escalate to a major accident.
Internationally, process safety management is recognised through OSHA 29 CFR 1910.119 and its 14 elements, and through the 20-element Risk Based Process Safety model from the CCPS (AIChE Center for Chemical Process Safety). In India, PESO, PNGRB and state factory inspectorates increasingly expect formal studies, and IFC Performance Standard 3 requires them for project-financed developments.
Process safety information, PHA, operating procedures, training, contractors, pre-startup review, mechanical integrity, hot work, management of change, incident investigation, emergency planning, compliance audits, trade secrets and employee participation.
Source: OSHA 29 CFR 1910.119, the widely adopted international PSM framework.
Our Approach
How We Deliver a Process Safety Study
A structured five-stage approach - independent, rigorous and built to give you outputs you can act on immediately.
Scope and Data
Define boundaries and gather P&IDs, process descriptions and the statutory requirements that apply.
Team Workshop
Facilitate structured, multi-disciplinary review sessions, on-site or remote, with the right people in the room.
Analysis
Apply the right method - HAZOP guide words, QRA modelling or HAC zoning - to each scenario.
Risk Evaluation
Score risk against tolerability criteria and expose the gaps in existing safeguards.
Report and Actions
Deliver a prioritised action register, a risk register and a management dashboard.
Sectors We Serve
Industries That Rely on Process Safety Management
Any facility handling hazardous chemicals, flammable materials or high-energy processes needs structured process safety management. Our consultants bring sector-specific method knowledge to each one.
What You Receive
Deliverables and Standards
Clear, actionable outputs, not just compliance paperwork. Every process safety study comes with a management-ready report and a prioritised action register.
Formal study report
All scenarios, consequences, existing safeguards and residual risk, fully documented.
Prioritised action register
Every recommendation scored by risk, with owner and target date.
Management dashboard
Heat maps and risk matrices for leadership review and progress tracking.
Area classification drawings
Zone drawings showing classified areas, extents and equipment guidance.
Standards We Work To
- IEC 61882 - HAZOP application guide
- IEC 60079 series - explosive atmospheres
- IS 5572 - hazardous area classification (India)
- OSHA 29 CFR 1910.119 - PSM standard
- IFC Performance Standard 3
- ISO 31000 and ISO 45001 - risk and OHS management
- PNGRB and PESO - India pipeline and explosives
Connected Work
Related Safety Services
FAQ
Process Safety Management, Your Questions Answered
What is process safety management (PSM)?
Process safety management is a systematic framework for preventing the unplanned release of hazardous material or energy from process equipment. It covers 14 elements, including process hazard analysis, mechanical integrity, management of change and emergency planning, that together prevent major fires, explosions and toxic releases in chemical, oil and gas, and pharmaceutical plants.
What does a process safety management programme include?
A full programme spans process safety information, hazard studies such as HAZOP and QRA, operating procedures, mechanical integrity, management of change, incident investigation, emergency planning and compliance audits. Consultivo delivers the study and audit elements and supports you in building the wider system.
What is the difference between HAZOP, HAZID and HIRA?
HAZID is an early, concept-stage workshop that names the major hazard categories before drawings exist. HAZOP is a later, guide-word review of finished P&IDs. HIRA is a broader hazard identification and risk assessment that builds a scored risk register across the facility. Most projects use HAZID first, then HAZOP, with HIRA maintained through operations.
When is a Quantitative Risk Assessment (QRA) required in India?
A QRA is expected when a site holds large inventories of toxic, flammable or explosive material above threshold quantities, when PNGRB rules apply to a pipeline or terminal, when an IFC or lender condition requires numerical risk demonstration, when a plant is sited near a population, or when insurers want evidence of individual and societal risk.
What is a PSM audit, and how is it different from a HAZOP?
A HAZOP finds hazards in a specific process design. A PSM audit is wider: it independently reviews your management systems, technical safeguards and operational disciplines against the 14 PSM elements and site practice, then reports a scored gap register with priorities and owners.
What are LOPA and SIL determination?
Layer of Protection Analysis (LOPA) is a semi-quantitative method that tests whether existing safeguards reduce a scenario to a tolerable level. Where they do not, it sets the required risk reduction and the target safety integrity level (SIL) for an instrumented protective function, in line with IEC 61511.
Is Consultivo an IFC-approved process safety consultant?
Yes. Consultivo is an IFC (International Finance Corporation, World Bank Group) approved independent consultant. That approval is recognised by development lenders, multilateral agencies and project finance banks as evidence of technical competence and independence, and is often a condition of financing for high-hazard facilities.
Which industries does Consultivo serve for process safety?
Consultivo delivers process safety studies for oil and gas, petrochemicals and refineries, bulk and speciality chemicals, pharmaceuticals and APIs, fertilisers, paints and coatings, food and beverage with ammonia refrigeration, power generation and mining, across India, SAARC countries and the Middle East.
Get Started
Talk to a Process Safety Consultant Today
Tell us about your facility, your process and what you need. We will come back within one working day with the right study and a clear next step.
- IFC-approved, genuinely independent consultants
- Proposals matched to your sector, regulator and sites
- Remote, on-site or blended delivery
Call +91 98311 45556 · hello@consultivo.in
