Process Safety, HSE & DSEAR Case studies

Below are examples of some of our more recent experiences. Get in touch if you would like to know more about the roles we took on any of these projects.

Process Safety, HSE & DSEAR Case Studies

Welcome to OTECSA Consulting’s case studies page, where we showcase our expertise and the real-world impact of our safety and risk management solutions. Our team of safety consultants has worked with businesses across diverse industries, delivering tailored services such as DSEAR risk assessments, HAZOP studies, and COMAH compliance support.

These case studies highlight the challenges our clients faced, the innovative strategies we implemented, and the measurable results achieved. From ensuring compliance for whisky distilleries to enhancing process safety management for large-scale operations, our work demonstrates our commitment to delivering excellence and protecting people, property, and processes.

Explore our case studies to see how OTECSA Consulting can help your business achieve its safety goals and maintain regulatory compliance.

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COMAH Calculations Case Study – Anaerobic Digestion Facility

An anaerobic digestion facility required clarity on its obligations under the Control of Major Accident Hazards (COMAH) Regulations, particularly in relation to the quantity of dangerous substances handled onsite, this is how we helped.

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Tank Storage Demolition DSEAR – Case Study

A major oil terminal operator engaged OTECSA to review an existing DSEAR risk assessment relating to the demolition of crude oil a storage tank at one of its terminal sites.

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Flammable Liquid Separation Distances: Storage and Ignition Source Guidance

Understanding flammable liquid separation distances is essential for safe storage design. Learn what HSG51 and HSG176 recommend for tanks, containers, and ignition sources.

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COMAH Tier Classification Assessment for an Anaerobic Digestion Facility Case Study

Learn how OTECSA carried out a COMAH tier classification assessment for an anaerobic digestion facility, helping the client understand regulatory thresholds and plan for future growth.

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HAZOP and LOPA Case Study: Fuel Depot BPCS Upgrade

This HAZOP and LOPA case study explores a fuel depot BPCS upgrade, identifying fuel release hazards, reviewing safeguards, and confirming proportionate protection measures.

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Electrostatic Risk Assessment for HDPE Drum Filling Case Study

A case study on electrostatic risk assessment for HDPE drum filling, highlighting ignition risks, compliance challenges, and practical controls.

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LOPA and SIL Determination in Practice at an Irish Distillery

OTECSA applied LOPA and SIL determination last month at an Irish distillery, supporting reliable safety systems and regulatory compliance.

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Onshore Oil and Gas HAZOP for a CAPEX Project

OTECSA Consulting completed an onshore oil and gas HAZOP to support a CAPEX project involving asset replacement on a mature operational site.

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Understanding ALARP and CBA in Process Safety: How Informed Decisions Protect Your Operations

This case study shows how ALARP and Cost Benefit Analysis helped evaluate safety improvement options for a bulk storage facility, enabling clear, justifiable decisions that met insurer expectations and strengthened process safety management.

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Simplifying HAZOP Updates for a Major Transport Hub

This HAZOP case study highlights how OTECSA helped a transport hub efficiently update its HAZOP during an upgrade project, maintaining compliance and reducing rework through effective change management.

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Embedded HSE Support at Rathburn Chemicals | Long-Term Safety with OTECSA

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Battery Rooms DSEAR

Battery charging produces hydrogen gas and requires DSEAR Risk Assessment. We explain the standards and requirements to comply.

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Whisky Distillery Process Safety: Managing Risks in Iconic Facilities

Whisky distilleries face significant safety risks due to flammable materials and high temperatures. Learn how OTECSA supports safer, sustainable production.

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Machinery ATEX and HAZOP

In 2024 OTECSA were engaged by a bespoke machinery manufacturer based in Scotland to support them on machinery ATEX aspects of design, and HAZOP support.

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Occupied Buildings Risk Assessment

The importance of OBRA in reducing risks from explosions, fires, and toxic releases. A brief explanation of OBRA and why it is important.

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CDOIF Environmental Risk Assessments for CoMAH

We help clients assess and manage Major Accident To The Environment (MATTE) risks through CDOIF environmental risk assessments. Using the Source-Pathway-Receptor model, we provide clear, practical solutions for CoMAH compliance.

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Challenges in HAZOP for Road Tanker Operations

Assessing Tanker Operations in HAZOP can be challenging. We have developed a proactive approach to get the most out of your study.

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Biogas DSEAR Risk Assessment

We have experience of carrying out DSEAR Risk Assessment at over 30 Anaerobic Digestion plants across the UK.

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DSEAR Training Delivery

After carrying out a site DSEAR update OTECSA have been on site at our client in the manufacturing sector providing DSEAR awareness training to their site operations team.

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Craft Distillery DSEAR Support

OTECSA is excited to be kicking off another Craft Distillery DSEAR Support project. Following on from other recent success in the sector, we're helping another client from the Highlands of Scotland.

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Process Safety for Distilleries

Process Safety for Distilleries includes several types of studies and an awareness of process safety management systems.

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DSEAR and ATEX for Whisky Warehouses

DSEAR and ATEX for Whisky Warehouses. This can be a complex assessment and requires knowledge of industry standards and ventilation requirements.

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Comprehensive Process Safety for Large Grain Distillery Site

Ensuring safety at a large grain distilery site with HAZOP and DSEAR. Comprehensive risk assessments for whisky and gin production.

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Ensuring Safety in Scotch Whisky Production

Safety at Scotch Whisky distilleries with HAZOP and DSEAR. Comprehensive risk assessments for three distilleries on one site.

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Process Safety in Precious Metal Mining

Implementing DSEAR safety measures for a precious metal mining site. Comprehensive risk assessment for fire and explosion hazards.

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Proactively Addressing Welding Hazards

Conducting a HAZID for safety in welding at an oil and gas waste treatment facility in Peterhead. Minimise risks, ensure safe operations.

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Landfill Site DSEAR

Comprehensive DSEAR assessment for landfill safety in Fife. Ensure compliance and mitigate risks with expert guidance.

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HSE Prohibition Notice Support

Expert support for HSE Prohibition Notice compliance. Ensure site safety with OTECSA's risk assessments and safety solutions.

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Case Study: Glen Turner and Glen Moray

Ensuring process safety compliance at Glen Turner and Glen Moray distilleries with DSEAR, HAZOP, and CoMAH risk management services.

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Car Garage DSEAR, Scotland

Conducting thorough DSEAR assessments for garage facilities to ensure safety in handling flammable materials across all sites.

Thank you for taking the time to explore our case studies and learn more about the work we do at OTECSA Consulting. These examples illustrate our commitment to providing tailored, effective solutions for businesses across Scotland and beyond. Whether it’s conducting DSEAR risk assessments, supporting COMAH compliance, or improving process safety management, our experienced team is dedicated to delivering measurable results that enhance safety and operational efficiency.

If you’re facing safety challenges or looking for expert guidance, we’re here to help. Get in touch with our team to discover how we can support your business with bespoke solutions that protect people, property, and processes. Together, we can achieve a safer, more secure future for your operations.

Get in touch

Interested in our offering or have a question about our DSEAR case studies? Use our contact details, or fill out the form below to get in touch with us.

0141 345 1985

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