Process Safety Consulting for the
Petrochemical & Refining Industries
Petrochemical plants and refineries operate under intense regulatory scrutiny and high process complexity. At Smith & Burgess, we specialize in process safety to help facilities mitigate risk, improve safety, and meet regulatory requirements; driving process improvements across the project's lifecycle.
Our consultants bring decades of experience solving technical challenges in refining and petrochemical operations—from relief and flare studies to engineering design reviews and corporate process safety management programs. Whether you’re navigating major capital projects or revalidations, our solutions are tailored to your facility’s design, operating conditions, and compliance requirements.
We work with producers of fuels, olefins, aromatics, polymers, and chemical intermediates with deep technical capabilities and a results-driven approach to process safety.
Supporting Process Safety for Next Generation Facilities
Our team serves petrochemical and refining clients through every phase—from early conceptual design to facility upgrades and expansions. We identify potential failure points, challenge assumptions, and optimize systems for safer and more efficient performance.
Pressure Relief & Flare System Studies
We conduct thorough evaluations of overpressure protection systems to ensure compliance with API 520/521, OSHA 29 CFR 1910.119, and internal standards. Our relief and flare system services include:
- Overpressure scenario identification
- Relief device sizing and documentation
- Flare system capacity and backpressure analysis
- Dynamic modeling to resolve system bottlenecks
- Mitigation planning for turnaround readiness
Our Salus software platform ensures documentation integrity and audit readiness, helping clients streamline data management across large portfolios.
Engineering Design Review & Verification
We verify that engineering deliverables meet industry standards, internal specifications, and relief system design best practices. Our design review services help ensure new units, revamps, and expansions are built for safety, reliability, and compliance. Services include:
- Review of PDFs, P&IDs, and datasheets for relief and flare systems
- Verification of equipment design pressures and specifications
- Relief load and disposal system integration checks
- Compliance validation against API, ASME, and corporate standards
- Recommendations to resolve deficiencies before fabrication or construction
Our early-stage involvement minimizes costly rework, reduces schedule risks, and ensures your facility meets both regulatory and operational expectations from day one.
Process Hazard Analysis (PHA)
Smith & Burgess provides facilitation and revalidation of PHAs using methodologies tailored to refining and petrochemical operations. We specialize in:
- HAZOP and What-If studies
- LOPA and SIL assessments
- Human factors and facility siting integration
- PHA team training and leadership development
Our facilitators have conducted studies for major U.S. refineries, complex petrochemical facilities, and integrated plants with interdependent units, ensuring coverage of both routine and non-routine scenarios.
Facility Siting Studies
We help clients assess potential impacts of fires, explosions, and toxic releases on occupied buildings and control rooms. Our facility siting services include:
- Consequence modeling per API 752/753
- Evaluation of existing mitigation measures
- Recommendations for building siting, design, or hardening
- Support for capital project planning and compliance audits
By combining regulatory expertise with practical engineering solutions, we help facilities improve occupant safety, maintain compliance, and enhance resilience against hazardous events.
When Compliance Isn't Optional
With OSHA and EPA oversight, as well as internal corporate mandates, refining and petrochemical companies face increasingly complex safety and documentation requirements. Our engineers are fluent in:
- OSHA PSM (29 CFR 1910.119)
- EPA RMP
- RAGAGEP (Recognized and Generally Accepted Good Engineering Practices)
- API, ASME, and corporate standards
We translate standards into actionable strategies tailored to your facility’s unique configurations and legacy infrastructure.
Proven Results. Trusted by Industry Leaders.
Smith & Burgess has delivered:
- Relief system revalidations at multiple major US refineries
- PHA revalidations and engineering reviews for global petrochemical manufacturers
- Facility siting studies for multi-unit, high-hazard petrochemical complexes
- Capital project support during FEED and detailed engineering phases
We operate with the discretion and technical depth required for high-stakes, regulated environments. Our track record is built on measurable results and long-term partnerships.
