Retrofitting process safety into an operating facility costs 10× more than integrating it during design. SafeGuard Projects embeds PSM expertise from FEED through startup — so your facility launches compliant, safe, and on schedule.
Most capital projects treat PSM compliance as a pre-startup checklist item. By then, the P&IDs are frozen, the equipment is installed, and change orders are expensive. The cost of fixing a hazard multiplies at every project phase.
A P&ID hazard caught in FEED is a drawing revision. Caught after construction, it's a field modification, a schedule delay, and a budget overrun.
Procedures, training programs, mechanical integrity plans, and emergency response plans can't be written in the final weeks before startup. They need to be developed in parallel with the project.
An operating facility has years of operational learning built in. A startup has none. First-of-kind operations, untested procedures, and new crews require process safety to be right from the first day of operations.
Source: Industry data on cost of change at each project phase. Early engagement is not an expense — it is cost avoidance at the largest possible scale.
Our lead consultant has served as Plant Manager and Technical Lead on some of the largest capital projects in the world — not as a compliance consultant, but as the person responsible for safe operations from day one.
One of Africa's largest LNG export terminals. Responsible for process safety integration from front-end engineering through plant startup, including all 14 PSM elements and PSSR sign-off before first feed.
Nigeria's gas-to-liquids megaproject — one of only a handful of commercial GTL facilities ever built. Deeply complex process chemistry requiring rigorous hazard analysis and process safety program development from first principles.
North America's most ambitious GTL megaproject, bringing world-scale gas-to-liquids technology to US soil. Both principal consultants contributed during the critical FEED phase, shaping process safety architecture, commissioning frameworks, and operational readiness programs before first steel.
One of the world's first large-scale commercial GTL plants, converting Qatar's vast natural gas reserves to liquid fuels. Operational role during the world's most ambitious GTL development period in the Middle East.
We integrate at every phase of your project — from the earliest design sketches through first feed.
Front-End Engineering Design review from a process safety lens. We identify hazards before the design is committed, when changes cost the least and have the greatest impact. Process hazard screening, facility siting considerations, and inherent safety assessment.
Systematic review of Piping and Instrumentation Diagrams against process safety requirements. Instrumentation completeness, relief system adequacy, isolation philosophy, human factors in control interface design, and RAGAGEP compliance of equipment specifications.
Hazard and Operability Study facilitation for new process designs. Unlike revalidation HAZOPs, new-design HAZOPs address unknowns, first-of-kind operations, and process interactions that have never been run in practice. We lead, document, and track every finding to resolution.
Building a 14-element PSM program from a blank page is the ideal engagement — no legacy program to untangle, no resistance to change. We develop your entire program in parallel with project construction: written plans, procedures, training curricula, and management systems ready for Day 1 operations.
Pre-Startup Safety Review (PSSR) development and execution. We work alongside your commissioning team to verify that all PSM elements are in place before any process fluid enters the equipment. Mechanical integrity verification, training confirmation, procedure validation, and safety system testing.
On-site process safety support during initial startup operations. The most hazardous period for any facility is the first operating campaign — new procedures, untested equipment, and crews running a process for the first time. We provide experienced process safety presence when it matters most.
Process safety is not a phase — it's a thread that runs through the entire project lifecycle. Here is where we integrate.
Hazard screening, facility siting, inherent safety assessment
We Engage HereP&ID review, HAZOP, relief system audit, PSI development
We Engage HerePSM program development, procedure writing, training design
We Engage HerePSSR execution, MI verification, system readiness confirmation
We Engage HereOn-site presence, MOC support, incident investigation readiness
We Engage HereOngoing PSM compliance — transition to SafeGuard PSM consulting
SafeGuard PSMOnce your facility is operational, our sister company SafeGuard PSM provides ongoing compliance consulting — creating a continuous relationship from construction through the life of the facility.
Capital investment in process industries is accelerating globally. Reconstruction, expansion, and new capacity are creating demand for process safety expertise at the project level — far from the nearest OSHA inspector, and where the cost of getting it wrong is catastrophic.
LNG export expansion, refinery modifications, new chemical capacity
Reconstruction, new petrochemical and refining capacity, infrastructure rebuild
Any greenfield facility where process safety must be built from a blank page
Most consultants show up before startup to check compliance boxes. We engage during FEED and detailed design — when a P&ID change costs a drawing revision, not a field modification.
No legacy program to work around. No embedded culture resistant to change. We build compliant, sustainable PSM programs from a blank page — the best possible starting condition.
When your facility transitions from startup to operations, SafeGuard PSM provides ongoing compliance consulting. One firm relationship from construction through the life of your facility.
Our team has studied 132 CSB incident investigations. Most catastrophic failures trace back to design decisions made years before the event. We know where to look.
Saves an estimated $10–$100 during construction and operations. The earlier the investment in process safety, the greater the return.
All 14 elements of 29 CFR 1910.119 must be in place before startup. We build them all, in parallel with your project schedule.
Every major CSB investigation in the database. We know the failure patterns. We know where programs break down. We build to avoid them.
When the PSSR is signed and first feed begins, your program is complete, your crew is trained, and your facility is compliant from the first day of operations.
Angola LNG · Escravos GTL · Sasol GTL · Oryx GTL Qatar. Not simulated. Not case-studied. Lived and operated.
Two consultants who came up through operations — not academia, not compliance offices. Decades of real process experience between them.
Distillation, reforming, hydrocracking, gasification, syngas conversion, amine treating, cryogenic fractionation, and more. The hazards look different in every unit — we know them all.
Process safety management consulting for operating facilities. Gap assessments, audit preparation, program development, and element-specific consulting for covered processes under 29 CFR 1910.119.
Operating FacilitiesCapital project process safety integration. FEED review, P&ID hazard analysis, HAZOP, PSM program development, commissioning support, and startup assistance for new construction and greenfield facilities.
Capital Projects & New ConstructionFree, authoritative reference for 29 CFR 1910.119. The complete regulation, all 30 OSHA Letters of Interpretation, Appendix A chemical database, PHA calculator, citation library, and PSM glossary.
Free Reference ResourceTwo consultants who have worked side-by-side across four companies and three continents. This is not a staffing agency. You get us.
Bruce has spent 40+ years operating and managing some of the most technically complex facilities on earth — from South African coal-to-liquids plants to West African LNG terminals. He has served as Plant Manager on projects totaling over $52 billion in capital investment, and he has operated 24+ distinct plant and unit types across five countries. When a project CEO asks "who have you actually done this with?" — the answer is Angola LNG, Escravos GTL, Sasol, Oryx Qatar, and Chevron.
Michael brings 35+ years in process operations, PSM program development, and regulatory compliance. He began as a field operator and progressed through lead operator, shift supervisor, and operations trainer roles across refineries, petrochemical facilities, and gas plants — in the United States and internationally. His work with Bruce began at Plant Automation Services and continued through Petro Star Alaska, Sasol, and Hunt — four consecutive employers, over 12 years of direct collaboration. That continuity of working relationship is a rare and deliberate advantage for clients.
The best time to engage SafeGuard Projects is the moment a capital project is approved. The second best time is now.
Every engagement starts with a conversation about your project — scope, timeline, phase of development, and where process safety needs to integrate. There is no commitment, no obligation, and no sales pitch. Just a direct conversation with experienced process safety professionals.