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Plant safety

Plant design/plant safety

Plant safety for operators in the process industry

Plant safety for operators in the process industry

Compliant with the law. Minimising risk. Operationally focussed.

In the chemical, petrochemical and energy sectors, plant safety is far more than just an approval criterion - it is an integral part of trouble-free, economical and legally compliant plant operation. Operators are responsible for ensuring that technical risks are recognised, assessed and controlled - and that all legal requirements are met.

1. legal obligations for operators of technical systems

Compliance with legal requirements is essential for the safe operation of process plants. The most important requirements include:

  • BImSchG & 12th BImSchV (Hazardous Incident Ordinance): Safety concepts and, if applicable, safety reports for accident-relevant operating areas.
  • BetrSichV & ArbSchG: Performance of risk assessments and implementation of technical and organisational safety measures.
  • GefStoffV & AwSV: Safe handling of hazardous substances and substances hazardous to water (e.g. retention volume, leakage detection).
  • Pressure Equipment Directive & Product Safety Act (ProdSG): Safe operation of pressurised components, pipelines and fittings.

2. technical safety during operation

Technical plant safety includes all measures to maintain the integrity of technical systems. This includes:

  • Safety-oriented design (e.g. pressure relief, functional safety).
  • Recurring tests of safety-relevant components.
  • Monitoring the integrity of safety functions (e.g. SIL tests).
  • Management of change for safety-relevant changes.

3. systematic risk analyses and verification

Proven procedures are used to identify and control potential hazards:

  • HAZOP/PAAG analyses: systematic evaluation of procedural processes.
  • SIL analyses (IEC 61511): classification and evaluation of control technology protection systems.
  • LOPA analyses: Evaluation of graduated protective measures for risk reduction.
  • Hazard assessments: fulfilment of the requirements of BetrSichV and ArbSchG.

These methods form the basis for legally compliant evidence for authorities, internal auditors and insurers.

4. organisation and operator responsibility

In addition to technology, clear organisational structures are essential for safe operation:

  • Responsibilities must be clearly defined and documented.
  • Employees and external companies must be instructed regularly.
  • Emergency and alarm plans must be up to date and tested.
  • Safety processes should be incorporated into an integrated safety management system (SMS).

As part of the TÜV NORD GROUP, we support operators of process plants in the implementation of technical and legal requirements:

  • Conducting HAZOP and SIL workshops.
  • Creation and maintenance of safety concepts and reports.
  • Support with authorisation procedures and operational changes.
  • Technical assessments in accordance with AwSV, BetrSichV and Hazardous Incident Ordinance.

Analysis & evaluation:

  • Hazard assessments (BetrSichV, GefStoffV)
  • Moderation and documentation of HAZOP/PAAG workshops
  • SIL considerations incl. loop definitions and verifications
  • LOPA analyses
  • Risk assessments for conversions or modifications
  • ATEX analyses (BetrSichV, GefStoffV)
  • ATEX analyses loop definitions and verifications
  • LOPA analyses
  • Risk assessments for conversions or modifications
  • ATEX zoning (if required)
  • Assessment of pressure equipment in accordance with PED and BetrSichV
  • Planning of safety-related systems (SIF, separation measures, pressure relief)
  • Selection & specification of safety-relevant components
  • Explosion protection documentation (if in scope)
  • Safety certificates and retrofit concepts
  • Support with EI&C technical implementation
  • Creation of safety concepts and reports
  • Communication with authorities and application support (e.g. BImSchG, WHG)
  • Documentation of protective measures and safety functions
  • Proof of conformity (BetrSichV, AwSV etc.)
  • Development or optimisation of safety management systems
  • Review of technical safety documentation
  • Preparation of audits and inspections by authorities
  • Training & workshops for operator managers
  • Advice on inspection obligations and deadline management

Because your project deserves more: Our services go beyond the standard

Our supplementary services create real added value: from digital project management and sustainability consulting to operational optimization - we support you throughout all project phases.