Protecting Facilities and People Through Process Safety
Prioritizing process safety reflects a strong commitment to protecting your workers, facilities, and operations from high-risk hazards in industrial environments. At G2, our accredited professionals provide expert assessments and tailored strategies that align with your operational goals to ensure safe, compliant processes.
Defining Process Safety in Industrial Settings
Process safety involves proactive risk management to prevent catastrophic incidents such as explosions, chemical releases, or equipment failures. It is the technical framework that keeps complex manufacturing and chemical operations running without life-threatening disruptions.
Critical Process Safety Hazards
Weak safety measures can lead to devastating consequences. We help you identify and mitigate:
- Combustible Dust: Risks in woodworking, metal processing, or food production.
- Hazardous Energy: Uncontrolled electrical, hydraulic, or mechanical sources.
- Machinery Risks: Inadequate guarding leading to amputations or lacerations.
- Airborne Contaminants: Toxic vapors or gases from faulty fume hoods or poor ventilation.
Regulatory Requirements: OSHA, NFPA, and ANSI
G2’s services are strictly guided by industry-leading standards to ensure your facility remains compliant:
- OSHA: 29 CFR 1910.147 (LOTO) and 29 CFR 1910.212 (Machine Guarding).
- NFPA: Specifically NFPA 652 for combustible dust.
- ANSI/ASHRAE: Standards 110 for fume hoods and 62.1 for ventilation rates.
The Cost of Process Safety Failures
Overlooking process safety can lead to costly downtime, heavy regulatory penalties, and a damaged reputation. OSHA frequently cites machine guarding and LOTO violations as top workplace safety issues.
Investing in safety today prevents catastrophic setbacks tomorrow.
Request Your Process Safety Assessment
Our Specialized Process Safety Assessments
Combustible Dust Hazard Analysis
Using NFPA 652 standards, we pinpoint dust accumulation and ignition sources in industries like grain, sugar, or aluminum processing. We provide practical recommendations for explosion venting and enhanced housekeeping.
Ventilation Assessments and Engineering
We measure airflow and contaminant levels against ASHRAE 62.1 benchmarks. Our goal is to optimize air quality, address design flaws, and improve filtration to keep your team breathing easy.
Fume Hood Testing and Certification
Ensure your labs and chemical plants are safe through ANSI/ASHRAE 110 testing. We conduct airflow measurements, containment checks, and smoke pattern analysis to verify performance.
Hazardous Energy Control (Lockout/Tagout)
We develop tailored LOTO procedures and conduct worker training to manage electrical and mechanical energy during maintenance. This reduces liability and helps prevent injuries and fatalities.
Machine Guarding and Engineering Controls
G2’s specialists evaluate machinery for hazards and recommend guards, barriers, or automated controls aligned with OSHA and ANSI guidelines to prevent severe injuries.
Process Hazard Analysis (PHA)
We provide a systematic approach to identifying, evaluating, and controlling the hazards of processes involving hazardous chemicals.
Get Expert Process Safety Help
Why Partner with G2 Consultants for Process Safety?
Accredited Technical Expertise: G2’s team consists of skilled professionals who deliver sharp, client-focused solutions rooted in the latest OSHA, NFPA, and ANSI standards.
Operational Alignment: We align our safety strategies with your specific operational goals to ensure compliance never hinders productivity.
Comprehensive Documentation: From detailed certification reports to regulatory records, G2 provides the clear evidence you need to satisfy inspectors and achieve peace of mind.
Our Technical Process Safety Evaluation Method
Hazard Identification and Risk Assessment
G2 Consultants performs detailed inspections to pinpoint dust accumulation, machinery gaps, and uncontrolled energy risks.
Engineering and Administrative Control Evaluation
We recommend physical barriers, automated controls, or procedural changes (like LOTO) to neutralize identified threats.
Testing, Inspection, and Certification
Our team conducts rigorous performance testing, including airflow measurements and smoke pattern analysis for fume hoods.
Documentation and Compliance Reporting
You receive actionable reports and compliance documentation that satisfy OSHA and NFPA requirements.
Ongoing Monitoring and Program Updates
G2 provides the training and practical guidance necessary to maintain safe operations and update programs as standards evolve.
Secure Your Process Safety Today
Process Safety Frequently Asked Questions
What is required in a Combustible Dust Hazard Analysis?
A Combustible Dust Hazard Analysis requires identifying dust accumulation areas, ignition sources, and compliance gaps under NFPA 652, followed by a plan to control these risks.
How often should lab fume hoods be tested?
Regular testing of fume hoods is required to verify they meet ANSI/ASHRAE 110 performance criteria and protect workers from toxic vapors.
What are the latest ANSI standards for machine guarding?
The ANSI B11 standard works alongside OSHA 29 CFR 1910.212 to define the requirements for guards, barriers, and automated controls.
How do you assess ventilation system effectiveness?
To assess ventilation system effectiveness, airflow and contaminant levels must be measured against ASHRAE 62.1 and OSHA benchmarks to ensure proper air exchange and filtration.
What is a Process Hazard Analysis (PHA)?
A PHA is a thorough evaluation used to identify and manage the risks associated with hazardous industrial processes.