Proven Strategies in Process Safety: Experience-Based Case Studies
This resource presents a collection of process safety case studies that highlight how real-world facilities have managed combustible dust and hazardous chemical risks. Each case study illustrates how hazard identification and risk mitigation techniques are applied in practice to reduce operational risks and maintain compliance.
Each case study includes:
Detailed site information and specific process conditions
Key concerns that informed the approach taken
Scenarios involving Dust Hazard Analysis (DHA) as defined by NFPA 652 for combustible dust hazards
Application of Hazard and Operability Study (HAZOP) as a PHA method per OSHA’s PSM standard (29 CFR)
Why Process Safety Case Studies Matter
These process safety case studies illustrate how the use of proven methodologies strengthens risk management and supports regulatory compliance while staying responsive to each facility’s operational needs.
By examining a variety of operational scenarios, this resource demonstrates how adaptable approaches effectively address complexities such as:
Hidden dust accumulation in enclosed systems and the risk of overpressure or secondary explosions
Electrostatic ignition hazards in pneumatic transport and material handling
Differences in dust properties leading to challenges in representative sampling and risk assessment
Overlapping hazards from simultaneous hot work and combustible dust operations
…as well as additional process complexities and challenges
Download Your Free Process Safety Case Studies
Fill out the form below to access our case study resource, showcasing how proven DHA and HAZOP methodologies identify process risks, support informed decision-making, and deliver targeted recommendations.
At Sigma-HSE, we provide data-driven insights and expert guidance to help you navigate complex process safety challenges. Contact us to learn how we can support your facility’s safety and compliance goals.
