VB SafeWatch is the productized process safety flagship. Bring us your P&IDs. We deliver HAZOP + LOPA + SIL determination + a 5-year IEC 61511 revalidation retainer that keeps the loops honest as the plant changes.
A HAZOP study is a moment in time. IEC 61511 says the safety lifecycle is continuous.
A plant that closed its HAZOP three years ago and added a compressor, a new feed line, and two SIL 2 loops without reopening the register is running unmanaged risk. That is the gap VB SafeWatch closes. HAZOP + LOPA + SIL are treated as one integrated lifecycle · every recommendation tracked to closure · every management-of-change event triggers revalidation · every safety instrumented function is proof-tested, evidenced, re-verified. When the auditor asks for the register on Monday morning, it opens in seconds.
Twelve years of brownfield HAZOP · LOPA · SIL work across refineries, petrochem, LNG, pharma, and specialty chemicals plants.
Every deliverable stands up to the toughest process safety audit. The retainer at Stage 05 is where recurring revenue meets IEC 61511 discipline.
P&ID walkdown · boundary definition · node discretization
Deviation analysis · cause-consequence · safeguards catalog
Initiating event frequency · IPL credit · mitigated frequency
SIL determination · verification · loop design
5-year IEC 61511 revalidation + management of change retainer
Boundary drawings are marked up on-site. Every process node is discretized against the P&ID revision that matches physical reality. Old drawings do not survive walkdown · they get redlined and re-issued before HAZOP starts.
Deviations from the drawing set are logged in the register with photographs, tie-in coordinates, and a proposed as-built resolution. The HAZOP that follows is discussing the plant that exists · not the plant the drawings remember.
Guide-word driven study, IEC 61882 compliant. Every deviation gets a documented cause, consequence, existing safeguard, and recommendation. We do not close a node until every consequence has either a credited safeguard or an open recommendation with an owner and a date.
Facilitator, scribe, and process safety engineer are all CEng MIE. The client team stays in the room for the whole study · this is not a black box handed back six weeks later.
Layer of Protection Analysis quantifies whether existing safeguards actually get the frequency of a consequence down to the tolerable risk criterion. Initiating event frequency, conditional modifiers, and IPL credit are documented against CCPS guidance.
The result is a mitigated frequency for every scenario · which then determines whether an existing SIF is credited correctly, whether a new SIF is required, and what target SIL that SIF needs to achieve. LOPA is the bridge from HAZOP to SIL.
SIL determination uses the LOPA output · calibrated risk graph or matrix as fallback where the client register demands it. SIL verification is a PFDavg calculation against IEC 61508 Part 6 formulae, using vendor-published or industry-recognised failure rates. We do not accept a marketing SIL claim without the certificate.
For loops that miss target SIL, we re-design · redundant sensors, voting logic, diagnostic coverage · until PFDavg lands inside the target band. Every SIF gets a proof-test procedure and a proof-test interval consistent with the assumed PFDavg.
The 5-year revalidation cycle is mandated by IEC 61511. But most plants only realise it 18 months before the audit. VB SafeWatch runs on an annual cadence · so on Year 5 the revalidation is a signature, not a rebuild.
Every management-of-change event is triaged against the recommendation register. Every new tie-in triggers a mini-HAZOP. Every SIF proof-test is logged and reviewed against its PFDavg. When the DDG-QA auditor walks in, the file is closed.
Every deliverable is written to withstand an audit by any regulator on this list. The signature at the bottom stands behind the code above.
Four things make VB SafeWatch different from a one-off HAZOP consultant. Every one is a productization decision that compounds over the retainer.
Practice Lead + Principal Reviewer both sign every deliverable. Two CEng MIEs looking at the same page · no drawing leaves with one signature.
The recommendation register lives in your CMMS or SharePoint · not our hard drive. Any auditor, any reviewer, any inspector opens the current state in seconds.
Every management-of-change event is routed through the register automatically. No forgotten HAZOP · no orphan SIF · no drift between drawing and plant.
Because the annual cadence holds, Year 5 revalidation is evidence review · not a rebuild. Compresses 18-month audit prep to 2 weeks.
Year 1 is the study. Years 2 to 5 are where the flagship earns its name. Where a plant carries a live continuous safety twin, the HAZOP register and SIF proof-test log push into Wistwin AviraTwin for real-time gas + safety monitoring.
HAZOP + LOPA + SIL determination + verification + SIS specification. Recommendation register handed to owner-operator. Baseline PFDavg documented.
Every management of change routed through the register. First round of SIF proof-tests witnessed. Any gap triggers re-verification.
PFDavg re-run against real proof-test data. SIF architecture adjusted if diagnostic coverage or demand rate has drifted from baseline assumption.
Open recommendations pushed to closure. Documentation gaps closed. Year 5 revalidation pack pre-staged.
Formal 5-year revalidation report. If the annual cadence held, this is a signature on evidence · not a rebuild. Auditor-ready.
Three brownfield process safety engagements delivered under the VB SafeWatch discipline. Names withheld · descriptive framing preserves technical integrity.
800 HAZOP nodes across three units. 62 LOPA scenarios credited. 34 new SIF requirements identified · 22 confirmed as SIL 1 · 12 as SIL 2. Proof-test cadence set at 12 months for SIL 1 and 6 months for SIL 2. Retainer live since Year 1.
Client SIL claims did not close. VB SafeWatch redid the PFDavg workbook from first principles · discovered 4 SIL 2 loops were running at SIL 1 architecture due to sensor diversity gap. Re-designed to 1oo2D with certified transmitters. Pre-commissioning delayed by 3 weeks · post-commissioning demand rate confirmed target SIL.
Client had missed the Year 3 mid-cycle review. VB SafeWatch executed a 90-day compressed revalidation · full register sweep, 6 MoCs retrospectively HAZOPped, all 18 SIF proof-tests witnessed, PFDavg re-run. Auditor accepted evidence. Zero deficiencies raised.
A 5-minute form. Practice Lead PSS routes to the process safety desk within 2 business hours. Every response signed by CEng MIE.
Bring us your P&IDs and your open recommendation register. We will show you what closure looks like.
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