Working closely with HSE, the aerosol manufacturing plant was assessed and a phased compliance plan was produced.

The compliance plan activities were determined by first carrying out an initial gap analysis of all activities carried out on site. The compliance process involved several key activities listed below:

• Area classification assessment.
• Production of area classification drawings.
• Inspection of all equipment in the hazardous area.
• Creation of equipment remediation plan.
• Provision of non-electrical equipment ignition hazard assessments.
• Creation of explosion protected equipment inspection policy.
• Analysis of site activities and provision of DSEAR risk assessments.
• Provision of portable electronic devices policy.
• SIL assessment of process safety instrumented system.
• Provision of DSEAR training to essential personnel.

4 Square provided a full DSEAR compliance and audit service for a major multi-national silicon wafer manufacturer. These services were provided at the request of the client which was seeking to ensure that process and operational safety had been maximised.

4 Square Engineering provided the services listed below:

• Chaired process plant HAZOP study for gas bunker, gas management, reactors
• Carried out DSEAR gap analysis of process plant
• Carried out plant equipment inspection / audit
• Reviewed existing hazardous area classification
• Provided policy for preventing ignition from portable electronic devices
• Reviewed existing DSEAR risk assessments

Following successful completion of the HAZOP and audit processes, improvement measures were identified and implemented to the satisfaction of the regulatory body (HSE).

4 Square provided a full DSEAR compliance and audit service for a major multi-national pharmaceutical products manufacturer. These services were provided at the request of the client which was seeking to ensure that process and operational safety had been achieved in terms of the UK regulations and also to satisfy the requirement to comply with internal audit procedures.

4 Square Engineering provided the services listed below:

• Chaired process plant HAZOP study
• Carried out DSEAR gap analysis of process plant
• Carried out plant equipment inspection / audit
• Carried out hazardous area classification study
• Provided hazardous area equipment management policy
• Provided policy for preventing ignition from portable electronic devices
• Provided DSEAR risk assessments

Following successful completion of the HAZOP and audit processes, improvement measures were identified and implemented.

The compliance plan activities were determined by first carrying out an initial gap analysis of all activities carried out on site.

The compliance process involved several key activities listed below :

• Area classification assessment of all surface works at the mine.
• Update of area classification drawings.
• Inspection of all equipment in the hazardous area.
• Creation of equipment remediation plan.
• Provision of non-electrical equipment ignition hazard assessments.
• Creation of explosion protected equipment inspection policy.
• Analysis of site activities and provision of DSEAR risk assessments.
• Provision of portable electronic devices policy.

4 Square provided an area classification analysis to enable the client to safely upgrade the conveyor system at the power station to handle the environmentally friendly biomass product on the conveyors in addition to coal.

The consultancy services provided included detailed analysis of the whole transportation system from material receipt through to the hopper loading area in the heart of the power station.

An area classification study was carried out taking into account the proposed modifications to the conveyor systems. The modifications to the system involved changes in the materials being handled in addition to the additional equipment to be installed to handle the new biomass material. The hazardous area classification study report provided enabled a clear and unambiguous equipment specification to be created with which to formalise the specification of the conveyor and dust extraction and conveyor spraying equipment.

The equipment inspection and process analysis carried out on site also identified several low cost improvements that could be implemented to significantly reduce risk in the process system.

As part of the ongoing waste water treatment and clean water treatment infrastructure improvement programme, 4 Square has been involved for over four years in the inspection and DSEAR verification of treatment works throughout the UK.

We have carried out inspection and verification activities in waste water and clean water treatment systems including those associated with ammoniation and chlorination systems.

Site activities include formal analysis of the key safety documentation (e.g. safety management systems, area classification, etc.) and inspection of installed equipment.

We also provide specific safety documentation for our clients including Explosion Protection Documents (EPDs), Zoning System Documents (ZSDs), Intrinsic safety system specification and certification documentation.

4 Square provided a preliminary COMAH applicability assessment for an existing and proposed gas holder / gas management system. Our analysis served to confirm that the site inventory did not fall within the terms of COMAH thereby alleviating the need for additional safety measures and controls.

In support of the COMAH applicability assessment 4 Square also provided blast wave modelling to define the scale of effects of the worst case explosion. This satisfied those aspects of DSEAR Regulation 6 requiring such assessment to be carried out.