Our Services
Comprehensive process safety and management systems consulting - technically rigorous, practically delivered.
Six Practice Areas. One Specialist Firm.
We cover the complete process safety lifecycle - from initial hazard identification through to ISO certification, PSM programmes and ongoing compliance.
Process Safety Engineering
HAZOP studies, LOPA, SIL/SIS assessments, dust hazard analysis (DHA), machine safety, electrostatic hazard studies, ATEX zoning and consequence modelling.
- HAZOP (Hazard & Operability Studies)
- LOPA (Layer of Protection Analysis)
- SIL / SIS Assessment (IEC 61511 / 61508)
- Dust & Combustible Material Hazard Analysis
- Electrostatic Hazard Studies
- Machine Safety - PSSR 2000 / Machinery Directive
- Process Consequence Modelling
- Reactive Chemical Hazard Studies
PSM Programmes
Design, develop, implement and independently audit comprehensive Process Safety Management programmes aligned to CCPS 20 elements and OSHA 1910.119.
- PSM Programme Design & Development
- PSM Gap Assessment vs CCPS / OSHA
- PSM Element Documentation
- Process Safety Culture Development
- PSM Training & Facilitation
- PSM Auditing & Performance Monitoring
- PSM KPI Framework Development
- Management of Change (MOC) Processes
ISO Management Systems
ISO 9001:2015, 45001:2018, 14001:2015, 22000:2018 and 27001:2022 - from gap analysis to certification readiness.
- ISO 9001:2015 - Quality Management
- ISO 45001:2018 - OHS Management
- ISO 14001:2015 - Environmental Management
- ISO 22000:2018 - Food Safety Management
- ISO 27001:2022 - Information Security
- Gap Analysis & Readiness Assessment
- Documentation & Procedure Development
- Internal Audit Programme & Pre-Certification Support
Quantitative Risk Assessment
Flash fire, thermal instability, energetic material evaluation, reactive chemical hazards and comprehensive QRA modelling.
- Flash Fire & Vapour Cloud Explosion Modelling
- Thermal Instability Studies (DSC / heat flow calorimetry)
- Energetic Material Evaluation
- Reactive Chemical Hazard Studies
- Toxic Release Risk Assessment
- Bow-Tie Analysis
- Risk Matrix Development
- COMAH / MHIDAS Major Hazard Assessment
Hazardous Area Classification
SANS 10108 and IEC 60079 zone classification, EI 15 explosive atmosphere study, NCOP 2022 and DSEAR 2002 compliance.
- SANS 10108 Zone Classification (RSA)
- IEC 60079-10-1 / -10-2 Zone Classification
- EI 15 Explosive Atmosphere Methodology
- NCOP 2022 Compliance Review
- DSEAR 2002 Assessments (UK / export clients)
- Hazardous Area General Arrangement Drawings
- ATEX / IECEx Equipment Selection Review
- Electrical Equipment Schedule Development
Technical Advisory
Flammability studies, dangerous goods advisory per ADR/SANS 10228, regulatory classification and turnkey project management.
- Flammability & Explosibility Testing
- Dangerous Goods Classification (ADR / SANS 10228)
- GHS/CLP Chemical Classification Review
- Regulatory Compliance Advisory
- Safety Data Sheet (SDS) Review
- Turnkey Safety Project Management
- Expert Witness & Incident Investigation Support
- PSSR 2000 Written Scheme of Examination
Machine Safety Inspections
Systematic machine safety assessments against EU Machinery Directives, ISO 13849, IEC 62061, EN 60204-1 and OSHA 29 CFR 1910 — risk assessments, safeguard evaluation and corrective action registers.
- Risk Assessment — ISO 12100 / ISO 12001-1,2
- EU Machinery Directive Conformity Assessment
- Control System Safety — ISO 13849 / IEC 62061 (PL / SIL)
- Electrical Safety Review — EN 60204-1:2018/A1:2025
- LOTO Programme Assessment — 29 CFR 1910.147
- Safeguard Type Selection & Safety Distance Verification
- Interlock Device Review — ISO 14119:2024
- Emergency Stop Verification — EN/ISO 13850
- OSHA 29 CFR 1910 Subpart O Compliance Review
- Non-Conformance Register & Corrective Action Plan
Our Engagement Methodology
Every Nexis Process Safety engagement follows a structured four-stage process designed to deliver thorough, compliant and implementable outcomes.
Scope & Assess
We begin with a thorough scoping session - understanding your operation, hazards, regulatory obligations and business objectives. We then conduct the relevant assessment: HAZOP, gap analysis, risk assessment or ISO readiness review.
Design
Our specialists design a tailored safety solution - whether a PSM programme framework, ISO management system structure, hazardous area classification study or risk reduction strategy. Solutions are always proportionate and context-specific.
Implement
We work alongside your teams to implement - developing documentation, facilitating training, coaching personnel and managing roll-out. We transfer knowledge throughout, not just at handover.
Monitor & Verify
We provide independent auditing, performance monitoring and corrective action planning - benchmarking your performance against international standards and identifying continual improvement opportunities.
Standards & Frameworks We Work With
Our consultants work across the full spectrum of international process safety and management systems standards.
Explosive Atmospheres
- SANS 10108
- IEC 60079-10-1
- IEC 60079-10-2
- EI 15
- NCOP 2022
- DSEAR 2002
- NFPA 497
- IEC 60079-0-17
Fire & Explosion Safety
- NFPA 86:2023
- NFPA 654
- NFPA 68
- NFPA 69
- NFPA 77
- EN 1127-1
- EN 13463
- EN 14460
ISO Management Systems
- ISO 9001:2015
- ISO 45001:2018
- ISO 14001:2015
- ISO 22000:2018
- ISO 27001:2022
- ISO 31000:2018
- ISO 31010:2019
Functional Safety / SIS
- IEC 61511 Ed3
- IEC 61508 Ed2
- ISA 84.01
- BS EN 62061
- ISO 13849-1
- PSSR 2000
PSM Frameworks
- CCPS PSM 20 Elements
- OSHA 1910.119
- API RP 750
- API RP 752
- API RP 753
- API RP 756
- COMAH Regulations
Dangerous Goods
- SANS 10228
- ADR 2023
- GHS Rev.10
- IMDG Code
- IATA Regulations
- UN Recommendations
Frequently Asked Questions
Common questions about process safety consulting and our services.
A HAZOP (Hazard and Operability Study) is a structured examination of a process or operation to identify hazards, operability problems and causes of incidents. You need a HAZOP when designing a new process, modifying an existing one, prior to major regulatory inspections, or as part of your PSM programme. HAZOP is required under several regulations and is considered industry best practice for high-hazard operations.
HAZOP identifies hazardous scenarios and proposes safeguards. LOPA (Layer of Protection Analysis) quantifies whether the existing safeguards provide adequate risk reduction for identified scenarios. HAZOP is qualitative; LOPA is semi-quantitative. They are typically used in sequence - HAZOP first to identify scenarios, LOPA to assess risk reduction adequacy for higher-consequence scenarios.
For a single facility with supportive management and dedicated resources, ISO 45001:2018 implementation typically takes 9-12 months from gap assessment to certification audit. Multi-site or complex organisations may require 12-18 months. Nexis Process Safety has achieved certification in as little as 10 months by using an intensive, structured implementation approach.
Hazardous area classification (SANS 10108 / IEC 60079-10) is the process of systematically identifying areas where flammable gases, vapours, dusts or fibres may form explosive atmospheres, and classifying them into Zones (Zone 0, 1, 2 for gas; Zone 20, 21, 22 for dust). Classified areas require specially certified electrical and other equipment to be used. Classification is a legal requirement under the OHS Act and relevant regulations.
Absolutely. We regularly assist organisations that have started an ISO implementation but need expert support to close gaps, strengthen documentation or prepare for a certification audit. We begin with a Gap Assessment to establish your current position against the standard requirements then design a targeted implementation plan to reach certification readiness efficiently.
Yes. We believe that sustainable process safety improvement requires knowledge transfer. All our engagements include explanatory sessions for key personnel. We also offer standalone training on HAZOP methodology, ISO management systems, process safety fundamentals and hazardous area classification for in-house SHEQ teams.