Risk Assessment | DSEAR and ATEX Experts

Pragmatic Risk Assessment and Actions

Our DSEAR risk assessments are designed to allow you to identify the highest risk areas of your process and efficiently allocate resources to mitigate these risks. Where an unacceptable risk is identified, pragmatic actions are provided which would reduce the risk towards As Low As Reasonably Practicable (ALARP) if implemented.

Each action is given a priority ranking relating to the risk and the hierarchy of control measures prescribed in Regulation 6 of DSEAR which will be collated in a live document that can be used to track the progress of each action and form the basis of your DSEAR compliance plan.

Our risk assessments are conducted in line with the requirements of Regulation 5 of DSEAR.

The HAC is usually performed at the same time as the hazardous area classification - learn more here.

What is DSEAR Risk Assessment?

A DSEAR risk assessment is an evaluation of the likelihood and severity of the hazards presented by dangerous substances in the workplace. The definition of a dangerous substance with some examples can be found here. DSEAR is primarily concerned with the fire and explosion hazards, but an often overlooked requirement is to also assess energy releasing events (such as inert gas cylinders acting as projectiles due to leaks) and corrosion which could lead to a fire, explosion, or energy releasing event.

Regulation 5 of DSEAR has specific requirements for what should be included in a DSEAR risk assessment. The findings must be recorded if there are five or more employees. The assessment must consider the following:

  • Hazardous properties of the dangerous substances

  • Circumstances of the work

  • Effect of existing safeguards and mitigation measures

  • Likelihood of an explosive atmosphere being present (typically taken from the Hazardous Area Classification - see here for more details).

  • Likelihood of effective ignition sources being present - EN 1127-1 contains 13 ignition categories which are typically used in assessments. ATEX equipment is also considered here - you can learn more about what ATEX markings mean here.

  • Anticipated effects of a fire or explosion - this depends on various parameters, such as quantity of the substances, congestion, confinement, and process conditions

  • Interconnected equipment and areas where fire or explosions could spread or propagate

  • Activities, such as maintenance, where there is potential for high risk - these are usually not covered in a DSEAR assessment as they are task-specific and typically form part of a Safe Systems of Work (SSOW) or Permit to Work (PTW) system on site

An important part of a DSEAR risk assessment is selecting an appropriate Basis of Safety (BoS) for each process (learn more here). The basis of safety essentially defines the principles and control measures used to prevent fire and explosions and is a summary of why the process is safe to operate.

Once the hazardous scenarios have been assessed in line with the requirements of DSEAR, the risks are typically ranked using a risk matrix. The most common is a 5×5 matrix, but other risk matrices can be used. Risk ranking is useful in order to help prioritise which risks should be most urgently addressed, and is typically the main metric for deciding where resources should be allocated. Other factors, such as cost, time, feasibility, and whether the improvement will give other benefits (e.g. ventilation improvements may also help manage COSHH hazards more effectively) will also factor into the risk picture.

Where the risk is deemed to be unacceptable, or a measure which is considered good practice is identified, recommendations are provided to reduce this risk to As Low As Reasonably Practicable (ALARP). To aid prioritisation, we assign a recommendation category in line with the hierarchy in Regulation 6 of DSEAR. This allows for prioritisation of actions (along with risk ranking) in line with DSEAR, so that resources (cost, time, effort) can be targeted at areas which will have the most impact.

DSEAR Dashboard

We collate all our recommendations into a tabulated list which can easily be exported to an action tracker (typically in MS Excel), where owners and deadlines can be assigned. We can also produce a bespoke risk dashboard to help manage the risks and allow direct comparison between different sites or site areas which may share the same capital projects budget. This allows you to track progress, allocate resources to achieve the highest amount of risk reduction with the resources available, and can be easily shared with regulatory bodies and stakeholders to demonstrate a roadmap to compliance.

DSEAR Risk Assessment Process

DSEAR risk assessment requires a strong knowledge of the process being assessed, and an in-depth understanding of fire and explosion hazards.

There are many parameters which must be considered, such as: the effects of congestion and confinement on the potential severity of an explosion, what type of ignition sources are credible and could be effective for the substances and process conditions, and how substances could interact with each other to create potential hazards.

Our experts are chemical or mechanical engineers have conducted hundreds of DSEAR risk assessments across a broad range of industrial sectors, meaning we will be able to accurately identify and assess your hazards.

Below is the a general overview of the DSEAR risk assessment process.

Step 1: Gather Data

The first step in a DSEAR risk assessment is to gather information on your site, processes and substances used. This includes:

  • Material properties (dusts, gases, and vapours)

  • Process descriptions and operating conditions

  • Drawings (site layout, PFDs, and/or P&IDs)

  • HAC documentation

  • Potential ignition sources

  • ATEX equipment asset register

  • Fire and explosion protection system details

  • Occupancy of areas

  • Emergency response plans

If there is an existing process, we will always conduct a site visit to gather data - there is no substitute for seeing the process in person!

For desktop-based assessments, we will send a tailored request for information to conduct the risk assessment based on our experience of similar processes. A desktop-based assessment will also require the overall explosion safety to be verified - learn more here.

Step 3: Conduct Risk Assessment

We conduct a risk assessment for every unit operation or process where a dangerous substance could be present. These mainly apply to fire and explosion hazards, but corrosion and pressurised releases must also be considered.

Our risk assessment is conducted in line with Regulation 5 of DSEAR, and considers various parameters, such as:

  • Scale and anticipated effects of the hazard

  • Likelihood of an explosive atmosphere being present

  • Likelihood of effective ignition sources being present (ignition sources are based on the categories given in EN 1127-1)

  • Potential for escalation to connected areas and equipment

  • Safeguards and mitigation measures in place

  • Occupancy of the area

We use a calibrated 5×5 risk matrix to rank the risks, clearly showing which risks are Broadly Acceptable, Tolerable if ALARP (TIFALARP) or Unacceptable.

Step 2: Select a Basis of Safety

For each process or unit operation, a basis of safety is selected. The basis of safety essentially defines the principles and control measures used to prevent fire and explosions and is a summary of why the process is safe to operate.

We assign the following categories to each process to document the basis of safety:

  • Inherently Safe Design

  • Prevention of the Formation of an Explosive Atmosphere

  • Control of Ignition Sources

  • Exclusion of Personnel

  • Explosion Mitigation

  • Good Housekeeping

A combination of basis of safety categories can be used (e.g. control of ignition sources in conjunction with explosion mitigation).

For more information, see our article on DSEAR Basis of Safety.

Step 4: Provide Pragmatic Actions

Where the risk is deemed to be unacceptable, or a measure which is considered good practice is identified, recommendations are provided to reduce this risk to As Low As Reasonably Practicable (ALARP).

We write our recommendations using “What, Why, Where” - this allows the actions to be standalone and understood without needing to refer to the report. Stating the “Why” also allows an alternative action to be completed which achieves the same outcome - this allows flexibility within your process and production constraints.

Each recommendation is assigned a category in line with the hierarchy in Regulation 6 of DSEAR. This allows for prioritisation of actions (along with risk ranking) in line with DSEAR, so that resources (cost, time, effort) can be targeted at areas which will have the most impact.

Risk Assessment Deliverables

For each DSEAR risk assessment, you will receive the following deliverables:

  • Report which contains:

    • A clear process description, including photos for clarity

    • Summary of the dangerous substances present and their explosive material properties

    • Risk assessment in line with Regulation 5 of DSEAR, with risks ranked using a calibrated risk matrix

    • Ignition hazard assessment in line with EN 1127-1

    • Pragmatic recommendations for each site area to reduce the risks towards ALARP

    • Collated recommendations list with DSEAR hierarchy prioritisation list

  • OPTIONAL - DSEAR Dashboard to help manage risks and allocate resources across multiple sites