Process safety engineering for Indian plants. HAZOP, QRA, LOPA, SIL determination (IEC 61511), safety audit, fire and explosion modelling, bowtie analysis, and a 5-year AMC retainer covering recertifications. Aligned to IS 13234, OISD-STD-129, OISD-GDN-180, PESO, Factories Act 1948 and CEA Regulations 2010. CEng MIE India sign-off on every deliverable. Designed to clear Factories Inspectorate, PESO, OISD and DGMS audit cycles. Hyderabad HQ + 9 site offices for field facilitation.
Every safety engagement is delivered as part of an integrated package tuned to Indian standards and Indian audit cycles. Optional 5-year AMC retainer keeps statutory recertifications current. CEng MIE India sign-off on every deliverable.
Node-by-node deviation study facilitated by IChemE-qualified Chair. Aligned to IS 14489 and OISD-GDN-180.
Quantitative risk assessment with PHAST, SAFETI and FRED. Aligned to OISD-STD-144 and PESO.
Layer of protection analysis with risk reduction factor sizing. Feeds SIL determination.
SIL 1 / 2 / 3 verification with PFD calculation. Aligned to IEC 61511 and IEC 61508.
Pre-startup, periodic and turnaround safety audits. Cleared for Factories Inspectorate and PESO.
Pool fire, jet fire, BLEVE, VCE and toxic dispersion modelling. Aligned to OISD-STD-116 and PESO.
Threat + barrier + consequence mapping for major accident hazards. Issued to plant safety case format.
Recurring HAZOP refresh, IS 13234 arc flash recertification, PESO renewal support and Factories Inspectorate audit packs.
Reliance · IOC · BPCL · HPCL · GAIL · ONGC · Adani · Grace · DuPont
TATA · JSW · AMNS · Jindal Steel · Hindalco · Aditya Birla
Pfizer · Bayer · Dr. Reddy's · Syngene · Aurobindo · Hetero · Natco
Adani · GMR · ITC · OPGC · NEEPCO · IOC LNG
Bureau Veritas · Lloyd's Register · Halliburton · Calderys · Asian Paints · Amazon · Mahindra
Marquee discipline: VB Engineering markets only brands from the Verified Client Roster. Case studies anonymised by NDA.
Representative engagements across Western India refining and petchem, Eastern mining belt steel and power, and South India pharma. Client names withheld under NDA.
A major Eastern Belt coal-fired power plant required a HAZOP refresh for two 660 MW units after a brownfield modification. IChemE-qualified Chair facilitated 22 nodes across boiler, turbine, BoP and ash handling. IS 14489 and OISD-GDN-180 framework. Factories Inspectorate audit pack issued.
Client name withheld · representative of multiple engagements in this category
A reputed Western Indian petrochem complex required a QRA for PESO licence renewal. PHAST and SAFETI used for jet fire, pool fire, BLEVE and toxic dispersion modelling. Aligned to OISD-STD-144 and PESO requirements. Iso-risk contours and societal risk F-N curves delivered.
Client name withheld · representative of multiple engagements in this category
A major South Indian pharma-formulations campus required SIL determination on an ammonia refrigeration system supporting sterile injectable cold chain. LOPA + SIL workshop facilitated. PFD verification in exSILentia. IEC 61511 and IEC 61508 aligned. CDSCO and PESO audit pack issued.
Client name withheld · representative of multiple engagements in this category
IS 13234 (arc flash), IS 14489 (HAZOP guideline), OISD-STD-129 (process safety management), OISD-STD-144 (QRA), OISD-GDN-180 (HAZOP and LOPA framework), OISD-STD-116 (fire protection), PESO requirements for hazardous-area facilities, Factories Act 1948 with state-specific Rules, CEA Regulations 2010 and DGMS for mining.
Yes. Every HAZOP report, QRA, LOPA workshop output, SIL verification, safety audit and AMC deliverable carries a Chartered Engineer (CEng MIE India) signature from a full-time staff Chartered Engineer registered with the Institution of Engineers (India).
Recurring HAZOP refresh on the agreed cycle (typically 5 years per OISD-GDN-180), IS 13234 arc flash recertification every 5 years, PESO licence renewal support, OISD audit pack maintenance, Factories Inspectorate audit support, and LOPA / SIL re-verification where modifications occur. Optional incident investigation included.
PHAST and SAFETI for consequence and risk modelling. FRED for free-field thermal radiation. exSILentia for SIL determination and PFD verification. PHA-Pro and HAZOP Manager for HAZOP recording. Aligned to OISD-STD-144 and ISO 17776 frameworks.
Yes. Our safety study deliverables are structured to clear PESO (Petroleum and Explosives Safety Organisation), OISD (Oil Industry Safety Directorate), DGMS (Directorate General of Mines Safety) and Factories Inspectorate audits without supplementary documentation. CEIG and Electrical Inspectorate audit support included.
IS 13234 (aligned to IEEE 1584-2018) recommends arc flash review every 5 years or after major electrical modifications. Factories Inspectorates increasingly cite arc flash as part of routine safety audits. The 5-year AMC retainer covers IS 13234 recertification along with PESO renewals and Factories Act audit packs.
1 to 14 weeks depending on scope. HAZOP for a process unit: 1 to 3 weeks of workshop plus 4 weeks report. QRA for a refinery: 8 to 14 weeks. SIL determination workshop: 1 to 2 weeks. Safety audit: 1 to 2 weeks. AMC retainer: rolling 5-year engagement. Site mobilisation typically 72 hours from Hyderabad HQ.
Yes. Threat + barrier + consequence mapping for major accident hazards is delivered in BowTieXP or similar. Aligned to OISD-GDN-180 framework and integrated with HAZOP, LOPA and SIL findings. Plant safety case format on request.
Tell us the plant type, the audit trigger, and the SIL target. We respond within one IST working day with a study scope, fee envelope, and a CEng MIE sign-off plan.
9 site offices for field mobilisation. Hyderabad analytical hub.
When the India regulator demands current process-safety documentation and the insurer demands current arc-flash labels, the combined Risk + Safety + AMC offer keeps both at the table. HAZOP + QRA + LOPA + SIL studies plus the 5-year recertification retainer.
Across the 21 refineries, 35 GW of thermal capacity, and 600+ industrial estates that anchor India's manufacturing base, the bundled risk + safety + AMC offer is what keeps the regulator audit cycle on schedule and the insurer at the table. India runs one of the most concentrated brownfield retrofit markets in the world: 21 refineries operating between 1965 and 2018 vintages, 35 GW of thermal capacity overdue for arc flash recertification, and a pharma cluster (Hyderabad, Visakhapatnam, Ahmedabad) where every API plant carries IS 5571 hazardous-area exposure. India's greenfield era is largely past for refineries and metals. The next decade of value comes from brownfield expansion, debottlenecking, and digital-twin handover on plants that are 15-40 years old. That is where every one of our last 1,000+ studies has happened.
HAZOP follows IEC 61882; LOPA follows the AIChE CCPS guideline; SIL classification follows IEC 61511; QRA modelling uses the CCPS guidelines for consequence and frequency. Arc Flash AMC uses IEEE 1584-2018 against NFPA 70E 2024. Where the operator references IS 3043 (earthing) · IS 5571 (hazardous area classification) · IS/IEC 60909 (short-circuit) · IS 13947 (LV switchgear), the deliverable structure aligns; the methodology is invariant.
Multi-disciplinary HAZOP led by a chartered facilitator. Deviation analysis at every node, cause-consequence-safeguard documented, recommendations ranked by priority. Where the India regulator demands HAZOP at a specified cadence (a 5-year cycle is common), we structure the engagement to match the calendar.
Frequency + consequence modelling for major hazard scenarios. Individual risk and societal risk contours where the operator boundary touches public land. The deliverable answers the regulator's "how safe is safe enough" question with a defensible number.
Independent protection layers documented; SIL requirements derived. The output feeds directly into the SIL assignment and the operator's safety-instrumented-function design or revalidation.
SIL classification per IEC 61511; SIL verification on the existing or proposed Safety Instrumented Functions using PFD and failure-rate data from the certified-equipment library. The deliverable closes the SIL-loop validation finding that most internal audits leave open.
Arc flash hazard calculation on the IEEE 1584-2018 method against NFPA 70E 2024. Labels printed in the India-appropriate format. The arc flash baseline becomes the entry into the 5-year AMC retainer.
Annual walk-down + change-impact assessment + re-labelling on equipment changes + 5-year full recertification. The retainer turns the recertification cycle from a panicked sprint into a managed cadence. AMC contracts are signed for 3-, 5-, or 7-year terms.
Three engagements that show how this works in practice across Indian brownfield plants:
a 220,000 BPD coastal refinery with 1996-vintage 132 kV intake.
The engagement: PESO 5-year renewal triggered relay coordination + arc flash + transformer-health re-baselining; existing SLD predated last DCS upgrade.
a USFDA-inspected API plant with Zone 1 process bays.
The engagement: A short-circuit incident at the LT panel during expansion forced unplanned EHS audit; client needed CEng-signed Arc Flash + Coordination study in 18 working days.
a 5 MTPA integrated steel plant with 220 kV captive power + EAF + LF + caster.
The engagement: Coordination drift on the EAF feeder caused nuisance trips on the rolling mill side; harmonic measurement + protection re-grading restored stability.
Buyer questions we hear consistently across PESO-renewal, CEIG-stamp, and OISD-117 conversations in India:
Tell us what risk + safety scope you need engineered in India. A practice lead responds inside 24 hours.
Scope Your Plant