Process Safety Risk Management

Achieve effective control of Process Safety Management risks.

Process Safety Management (PSM)

Risk Consulting

IFO Group specializes in Process Safety Management and Risk Management Plan (RMP) consulting, which are vital for preventing incidents involving highly hazardous chemicals, as defined by both OSHA and EPA. PSM encompasses a comprehensive set of strategies and procedures aimed at reducing the frequency and severity of chemical and energy source releases within applicable industries.
Process safety incidents, involving toxic, reactive, or flammable substances, can occur across various industries. When these highly hazardous chemicals are not adequately controlled, the potential for accidents and disasters looms large. To address this, OSHA has outlined stringent requirements in the Process Safety Management of Highly Hazardous Chemicals regulation (Title 29 of CFR 1910.119) to ensure safe workplaces.
IFO Group has a global track record of assisting clients in effectively managing process safety risks and achieving regulatory compliance. Our approach involves providing unbiased and practical guidance, helping build enduring client relationships by consistently delivering high-quality results, adhering to timelines and budgets, and leveraging industry-leading business processes, robust project management, and effective quality assurance measures.

Benefits of Using IFO Group

Using IFO Group for Process Safety Risk Management services offers several significant benefits:


 IFO Group boasts of team of experienced professionals who are well-versed in process safety risk management.

Regulatory Compliance

IFO Group consultants are knowledgeable about industry regulations and standards including OSHA’s Process Safety Management (PSM) regulations. We can help your organization ensure compliance reducing the risk of regulatory penalties.

Unbiased Advice

 IFO Group provides unbiased and pragmatic advice, ensuring that recommendations are based on the best interests of your organization and not influenced by external factors.

Process Industries Served


Cold Storage / Ammonia Refrigeration Operations

Explosives Manufacturing (Fireworks, Ammunition)

GTL (Gas to Liquids)

Hazardous Materials Warehousing and Logistics

Paper and Pulp

Power Generation

Upstream Oil and Gas (onshore and offshore)

Chemical and Specialty Product Manufacturing

Compressed and Cryogenic Gases

Hazardous Materials Warehousing and Logistics

Power Generation

LNG (Liquified Natural Gas)

Paints and Adhesives Manufacturing


Refining and Petrochemical

Midstream Oil and Gas

Refining and Petrochemical

Process Safety Management (PSM) Risk Services:

IFO Group PSM Consultants have extensive experience in providing third-party independent process safety assessments and PSM audits to clients with diverse operations.

IFO Group will help you with the identification of risks involved in the design, operation and modification of processes that handle highly hazardous chemicals. Our expert consultants utilize a full range of PHA services including HAZOP studies, LOPA studies, HAZID studies, FMEA, Fault Tree Analysis, HAZOP studies, What If / Checklist studies and Bow-Tie Assessments.

Hazardous Area Classification (HAC) or Electrical Area Classification (EAC) is a method of analyzing and classifying the environment where hazardous atmospheres may be present to then facilitate the proper selection and installation of electrical equipment safe to use in that environment. IFO Group consultants perform area classification assessments in accordance with recognized U.S. and international standards and guidelines applicable to each project.

Process Safety Management (PSM) Risk Services:

What can we do for you?

IFO Group auditors have extensive experience in providing third-party independent process safety assessments and PSM audits to clients with diverse and complex operations.


Our expertise includes process safety incident investigation expert witness services. IFO Group auditors actively engage with the client and independent investigation teams. This breadth of experience helps us provide insights into the latest regulatory priorities and common gaps, drawn from our own management system and incident investigation experience.

Tailored Approach

We understand that every client is unique. That is why we customize our approach to meet your specific needs. Our collaborative philosophy underscores our belief that PSM audits and assessments should foster continuous improvement rather than punitive measures. Our goal? To help you prevent the next major incident.


IFO Group auditors have extensive knowledge when it comes to PSM regulatory requirements and industry standards. With a primary focus on developing and implementing specialized and integrated management systems, we are at the forefront of ensuring compliance.


Once you entrust us with your project, you can count on clear and consistent communication. Our auditors prioritize regular updates, ensuring you are involved at all times. Our reports are well-written and include relevant references to ensure the information you receive is valuable and actionable.


The conduct of our audits conforms to the 'Standards for the Professional Practice of Environmental, Health & Safety Auditing' and the 'Competency Framework for Environmental, Health & Safety Auditors' as adopted by the Board of Environmental Health & Safety Auditor Certifications (BEAC) and the Institute of Internal Auditors (IIA).


Consulting Services: Types of Operations Served

Representative Capabilities

IFO Group consulting experts specialize in conducting comprehensive three-year compliance audits, ensuring adherence to OSHA PSM and EPA RMP Standards.

Our commitment to clients extends beyond the audit site. We remain readily available to answer questions and offer guidance on corrective actions. Your compliance journey is our priority.


Hazard Analysis

At IFO Group, weIn the United States, the use of Process Hazard Analysis (PHA) is mandated by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA). The Process Safety Management standard mandates the identification of risks involved in the design, operation, and modification of processes that handle highly hazardous chemicals.
IFO Group consultants can provide a full range of PHA services to include HAZOP studies, LOPA studies, HAZID studies, FMEA, Fault Tree Analysis, HAZOP studies, take pride in ensuring the robustness and reliability of your assets through our comprehensive Mechanical Integrity services. Trust us to safeguard your operations with precision and expertise.


An IFO Group facilitator works with your designated team of people to conduct a HAZOP study. Our facilitator is responsible for guiding your team’s brainstorming and discussion of causes and consequences of possible incident scenarios. Then the team is led through an open forum to formulate recommendations for appropriate corrective actions. If desired, we can also provide a study scribe to expedite and streamline the HAZOP study documentation.

LOPA (Layer of Protection Analysis) Studies

A Layer of Protection Analysis (LOPA) Study is used in conjunction with other PHA techniques, especially HAZOP, to determine if there are sufficient layers of protection against an identified high-risk incident or scenario. It can also be used to ensure additional safeguards are in place to reduce risk to a tolerable level. LOPA studies are also commonly used to identify Safety Integrity Level (SIL) values required for Safety Instrumented Functions (SIF) in Safety Instrumented Systems (SIS) to comply with the IEC 61511 / ISA S84 standards.

HAZID (Hazard Identification) Studies

A Hazard Identification Study (HAZID) is a high-level, systematic study of process hazards that uses checklists of hazards to identify materials, systems, processes, and facility characteristics that could produce undesirable consequences through the occurrence of an incident. HAZID studies are frequently used for the early identification and assessment of hazards to provide critical input for project decisions at a time when design changes would have minimum cost penalties. The HAZID Study is a crucial part of a project’s risk assessment and is typically a key milestone to complete in the Conceptual and Front-End Engineering Design (FEED) phases of capital projects. It is conducted by a multi-disciplinary team using a structured, brainstorming approach, guided by checklists and guide words. For each identified hazard, the team discusses potential causes, the consequences of those causes, the safeguards and mitigation measures present within the design to address those hazards, and any necessary recommendations to reduce the risk of the scenario.

Bow Tie Assessments (BTA)

Bow Tie Assessments (BTA) are a systematic method for graphically analyzing and demonstrating causal relationships in plausible high-risk scenarios involving a given hazard. Control measures are then documented to demonstrate current risk mitigations. Finally, the failure scenarios or conditions aka the ‘escalation factors’ for the control measures are identified. Bow Tie Analysis can also be effectively used in conjunction with appropriate process safety management systems to demonstrate that major hazards for an organization are being managed to ALARP (As Low as Reasonably Practicable).

What If? Studies

The What-If? Study is a high-level systematic method for examining the responses of process systems to equipment failures, human errors, and abnormal process conditions. This technique requires participation by team members who know and understand the basic hazards associated with the process and its operation. The facilitator assists the client’s team with developing “what-if” questions about the process (e.g., “What if the pressure relief valve fails to open as expected?”). By answering these questions, the team identifies potential hazards and suggests ways to improve safety. The results of a What-If Analysis are documented by listing the specific questions, responses, and recommendations generated by the team. One of the strengths of this method is that it can be applied to any system at any stage of its design, development, or operation.

Failure Mode and Effects Analysis (FMEA)

The failure mode and effects analysis (FMEA) technique is a methodical study of system component failures. All failure modes for each component in a system are identified and the effect of each component failure on the overall system is evaluated. This technique is most commonly used for processes that do not involve reactive chemistry but can be effectively used for interlock and emergency shutdown (ESD) systems.

Representative Capabilities

Our consultants can team with your staff to provide a full range of PHA study related services by:

A Hazard and Operability Study (HAZOP) is a structured and systematic PHA of a planned or existing process or operation in order to identify and evaluate problems that may represent risks to personnel, equipment, the environment or efficient operations. HAZOP is a qualitative technique based on guide words and is conducted by a multi-disciplinary team.


Area Classification

We can help!  IFO Group consultants can quickly and efficiently help you revise an existing Hazardous Area Classification drawing or provide you with an assessment of a new project.   Just click on the “Request a Consultation” button on the right side of this page, call us, or send us an email and we’ll be happy to provide you with a free consultation to discuss your needs!

Hazardous Area Classification (HAC) or Electrical Area Classification (EAC) is a method of analyzing and classifying the environment where hazardous atmospheres may be present so as to facilitate the proper selection and installation of electrical equipment to be used safely in that environment. When electrical equipment is used in, around, or near an atmosphere that has hydrocarbons in the form of flammable gases, vapors, or liquids, combustible dusts, or ignitable fibers, there is always a possibility or risk that a fire or explosion might occur.   Proper Hazardous Area Classifications are a key part of process safety risk management and should be updated and maintained as part of an overall Process safety Management (PSM) program.
Those areas where the risk of fire or explosion might occur due to an explosive atmosphere and/or mixture is often called a hazardous (or classified) location/area.
Currently, there are two systems used to classify these hazardous areas for electrical equipment:

Area Classification Assessments by IFO Group

IFO Group performs area classification assessments in accordance with recognized U.S. and international standards and guidelines applicable to each project such as OSHA 1910.307, NFPA 70 – National Electrical Code Handbook, NFPA 497, NFPA 499, API RP 500, API RP 505, IEC 60079, and ISA 12.10.

  1. Hazardous material identification (flammable gases or vapors, combustible dust, or ignitable fibers).
  2. Selection of risk assessment methodology.
  1.   Obtain needed documentation such as process drawings, plot plans, safety data sheets, heat and material balances and basis of design information.
  2.  Determine the reach of the classified area around each point source. Gas and vapor dispersion modeling software will be needed on a case by case basis for an accurate determination.
  3. Develop the hazardous area classification drawing(s) that reflect all of the point sources. This will include plan and elevation views.
  4. Compile a detailed project report that clearly documents the method and rationale for the area classifications, process safety information, a detailed list of all identified point sources, assumptions, and the results of the dispersion modeling software (if used).

Visit our services page to see all our service offerings!

PSM Resources

Explore the IFO Group blog to access invaluable information on a wide range of Process Safety Management topics.

Questions? Contact Us

Request a consultation and we’ll get back to you within a few hours. Want to talk to us now? Call our 24 HR number! +1-832-403-2135


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