Process Safety Services
Managing process safety means understanding your hazards and maintaining the programs, safeguards, and information needed to control them as your facility changes. Cognascents Consulting Group provides integrated process safety services that help organizations strengthen compliance, make informed risk decisions, and protect people, facilities, and surrounding communities.
PROCESS SAFETY SERVICES
Nine services, one integrated approach.
A strong process safety program connects management systems to the engineering and operating practices that prevent serious incidents. Our services help you identify hazards, address gaps, and build programs your team can maintain.
|
PROGRAM-LEVEL
PSM Program Development and SupportBuild, implement, and maintain an integrated Process Safety Management (PSM) program under OSHA 1910.119, that connects its elements and reflects your facility’s operations. |
RMP COMPLIANCE
Risk Management Program (RMP) Development and SupportConnect hazard assessments, prevention programs, and emergency planning into a Risk Management Plan (RMP) that supports EPA RMP compliance under Clean Air Act Section 112(r). |
AUDITS & VERIFICATION
PSM/RMP Compliance AuditsIndependent PSM and RMP audits under OSHA 1910.119(o) and EPA 40 CFR 68.58/68.79, combining document review, interviews, and field observations into findings your team can act on. |
||
|
HAZARD IDENTIFICATION
Process Hazard Analysis (PHA)HAZOP, LOPA, What-If, HAZID, and FMEA facilitation under OSHA 1910.119(e), prep-heavy and AI-accelerated, from facilitators who have led thousands of PHAs across the industry. |
PROCESS SAFETY INFORMATION
Process Safety Information (PSI) SolutionsDevelop, verify and organize the drawings, datasheets, and design documents required under OSHA 1910.119(d), so hazard studies and operating decisions have a reliable foundation. |
OPERATING BOUNDARIES
Safe Operating Limits (SOL) DevelopmentEngineering-defined limits that tell operators when normal operation ends and protective action must begin, built from process safety time and response capability, not a datasheet value copied into a procedure. |
||
|
CONSEQUENCE & SITING
Facility Siting StudiesBlast, thermal, and toxic dispersion modeling for occupied buildings per API RP 752, 753, and 756, so siting and protection decisions come from credible scenarios, not assumptions. |
FINDING RESOLUTION
Open Recommendations ResolutionPrioritize and resolve PHA, audit, and incident investigation findings with feasible actions and a documented basis for closure. |
BUILDING CAPABILITY
Process Safety Training SolutionsPSM awareness, facility-specific training, and HAZOP/LOPA facilitation instruction that connects engineering principles to your team’s day-to-day responsibilities. |
||
Why Cognascents
Why choose Cognascents as your process safety consulting firm
Practitioner-Led Expertise
Experience Across the Process Safety Program
Our engineers facilitate PHAs, conduct audits, and develop and implement PSM and RMP programs across a range of industries. We bring experience from both assessing programs and helping facilities put them into practice, so recommendations are grounded in how facilities operate. |
AI-Accelerated Delivery
Faster Analysis, Same Engineering Depth
Our proprietary AI tools accelerate documentation, data extraction, and preliminary gap identification across PSM and RMP work, from PHA worksheets to process safety information review. Engineers still validate every finding and sign off on every deliverable, so the depth of review doesn’t change, only the time it takes to get there. |
Integrated Engineering Team
Process Safety and Asset Integrity Together
Cognascents combines process safety and asset integrity expertise in one integrated engineering team. Mechanical integrity gaps surface consistently in our PSM audits, PHA and open recommendation findings often connect to relief, SOL, or procedure work, and the same specialists who support hazard analysis also support the facility-wide compliance and inspection programs built around it. |
Standards & Codes We Work To
The industry standards and regulatory frameworks that govern process safety across the chemical and hydrocarbon processing lifecycle.
Process Hazard Analysis
OSHA 29 CFR 1910.119(e)EPA 40 CFR 68.67CCPS Guidelines for Hazard Evaluation Procedures
PSM & RMP Compliance Audits
OSHA 29 CFR 1910.119(o)EPA 40 CFR 68.58, 68.59, 68.79, 68.80Applicable RAGAGEP
Facility Siting
API RP 752API RP 753API RP 756EPA 40 CFR 68.67(c)(5)CCPS Guidelines for Evaluating Process Plant Buildings
Risk Management Program
Clean Air Act Section 112(r)EPA 40 CFR Part 68
Process Safety Information & Recommendation Closure
OSHA 29 CFR 1910.119(d), (e)(5), (m)(5), (o)(4)EPA 40 CFR 68.67(e)
PSM Program Foundations
OSHA 29 CFR 1910.119CSA Z767CCPS Risk Based Process Safety Guidelines
PROCESS SAFETY AND ASSET INTEGRITY, ONE FIRM
Talk through your PSM or RMP program with an engineer who has built one.
Tell us where your hazard analysis, information, or compliance program keeps you up at night. We will tell you which of these services actually fits, with no sales process in between.
Want background first? Keep reading for articles and case studies from the engineers who do this work. ↓↓
Related Content
Process safety articles and case studies
Technical articles and case studies from the engineers who lead these engagements.
|
ARTICLE | PROCESS SAFETY
Developing a Robust PSM Program: A Practical RoadmapA practical look at building a PSM program from scratch, including the planning and technical discipline it takes to make it sustainable. |
CASE STUDY | PROCESS SAFETY
Process Hazard Analysis (PHA) Independent ReviewAn independent review of a facility’s PHA program after a disproportionate volume of recommendations raised questions about their validity. |
CASE STUDY | EV BATTERY MANUFACTURER
Fortifying Critical PSM Program Elements for a Lithium-Ion Battery ManufacturerStrengthening and hardening a PSM program for an EV battery manufacturer handling flammable and reactive chemicals. |
Talk to a process safety engineer about where to start
Tell us what is happening with your process safety program. One of our engineers will give you a straight answer about where to start.