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Process Safety & Risk Management Solutions

Here at Gexcon, we have teams of experienced consultants ready to assist you in identifying all your hazards, understanding your risks and contributing to improving your company’s overall safety performance. The diverse background of our team assures that our consultancy services can advise you on all aspects of safety and risk throughout all your facilities, no matter how complex they might be.

  • Software Solutions

  • Consulting

  • Fire & Explosion Testing

  • Certification

Your global process safety partner

With over 40 years of experience in process safety we believe in tailor made solutions for each client

Safety beyond regulatory compliance

At Gexcon, we understand that safety is more than just meeting regulations; it's an investment that pays dividends in proactive risk management, operational efficiency, and the well-being of your workforce. By prioritising safety, you enhance your organisation's resilience and reputation in a dynamic and competitive industry. Join hands with us to ensure safety in your facilities.
Sectors we serve

We deliver services within a wide range of sectors. Select your sector to discover more.

  • Oil & Gas
  • Petrochemicals & chemicals
  • LNG
  • Hydrogen
  • Renewables
  • Energy
  • Dust in process industries
  • Automotive & Aerospace
  • Food & Beverage
  • Pharmaceutical
  • Equipment manufacturing
Case studies

Discover how we aid clients through real-world examples in our case studies.

  • All sectors
  • Oil & Gas
  • LNG
  • Hydrogen
  • Automotive
  • Dust in process industries
  • Petrochemicals & chemicals
  • All services
  • Process Hazard Analysis
  • Global regulatory compliance
  • Incident Investigation and Expert Witness
  • FLACS

  • Oil & Gas

    Toxic and flammable gas cloud detectors layout optimization using CFD

    Oil & Gas

    Toxic and flammable gas cloud detectors layout optimization using CFD

    What you will learn

    • CFD allows the effect of geometry, ventilation and leak characteristics to be taken into account, producing more accurate results which lead to a more economical and cost-effective solution CFD allows the effect of geometry, ventilation and leak characteristics to be taken into account, producing more accurate results which lead to a more economical and cost-effective solution
    • Simulation work has shown that CFD modelling would account for complex gas cloud shapes and sizes and would induce a higher conservatism compared to simpler models Simulation work has shown that CFD modelling would account for complex gas cloud shapes and sizes and would induce a higher conservatism compared to simpler models

  • Petrochemicals & chemicals

    DSEAR Compliance Analysis – Hand Sanitiser Manufacturing

    Petrochemicals & chemicals

    DSEAR Compliance Analysis – Hand Sanitiser Manufacturing

    What you will learn

  • LNG

    Pre-Operations Safety Report for LNG Storage Facility

    LNG

    Pre-Operations Safety Report for LNG Storage Facility

    What you will learn

    • CFD modelling provides strong support in both the predictive and technical aspects of the COMAH Safety Report, showing clear justification for the design of mitigation measures. CFD modelling provides strong support in both the predictive and technical aspects of the COMAH Safety Report, showing clear justification for the design of mitigation measures.
    • A thorough and systematic approach enables the identification of additional risk reduction, allowing changes to be implemented while minimising cost and disruption and ensuring the safety of the facility going into operation. A thorough and systematic approach enables the identification of additional risk reduction, allowing changes to be implemented while minimising cost and disruption and ensuring the safety of the facility going into operation.

  • LNG

    The effects of terrain modelling on risk contours for a Liquid Biogas (LBG) plant

    LNG

    The effects of terrain modelling on risk contours for a Liquid Biogas (LBG) plant

    What you will learn

    • Terrain has a significant influence on the dispersion of flammable gas Terrain has a significant influence on the dispersion of flammable gas
    • Terrain effects can be realistically modelled using CFD Terrain effects can be realistically modelled using CFD
    • Realistic modelling of dispersion improves the understanding of risk and gives better decision support for a cost-effective plant design and operation Realistic modelling of dispersion improves the understanding of risk and gives better decision support for a cost-effective plant design and operation
    • 3D risk contours can be calculated and presented in a realistic terrain model using FLACS-CFD 3D risk contours can be calculated and presented in a realistic terrain model using FLACS-CFD

  • Hydrogen

    Accidental hydrogen release management in a proton accelerator tunnel

    Hydrogen

    Accidental hydrogen release management in a proton accelerator tunnel

    What you will learn

    • Realistic geometry modelling of installations has significant influences on the accuracy and reliability of the results Realistic geometry modelling of installations has significant influences on the accuracy and reliability of the results
    • How confinement and ventilation can influence the gas dispersion process How confinement and ventilation can influence the gas dispersion process
    • Realistic modelling of hydrogen gas dispersion improves the understanding of risk and gives better decision support for the cost-effective implementation of preventive and mitigative measures in the facility Realistic modelling of hydrogen gas dispersion improves the understanding of risk and gives better decision support for the cost-effective implementation of preventive and mitigative measures in the facility

  • Automotive

    DSEAR Compliance Analysis – UK Car Manufacturing Facility

    Automotive

    DSEAR Compliance Analysis – UK Car Manufacturing Facility

    What you will learn

    • How CFD can be used to model complex geometries especially where obstructions can create dead spots in ventilation domains How CFD can be used to model complex geometries especially where obstructions can create dead spots in ventilation domains
    • Performing dispersion and ventilation modelling studies can demonstrate risk to be as low as reasonably practicable (ALARP) Performing dispersion and ventilation modelling studies can demonstrate risk to be as low as reasonably practicable (ALARP)
    • CFD modelling can highlight where risks can be reduced and help inform the design, resulting in a more economical and cost-effective solution CFD modelling can highlight where risks can be reduced and help inform the design, resulting in a more economical and cost-effective solution
    • Providing support at the early stages of any project can highlight areas where risks may be reduced and help inform the design Providing support at the early stages of any project can highlight areas where risks may be reduced and help inform the design

  • Petrochemicals & chemicals

    Investigation findings and lessons learned in the West Fertilizer explosion

    Petrochemicals & chemicals

    Investigation findings and lessons learned in the West Fertilizer explosion

    What you will learn

    • Summary of the West Texas Fertilizer explosion incident: cause and damage Summary of the West Texas Fertilizer explosion incident: cause and damage
    • Understand the unique set of conditions necessary for the explosive decomposition of ammonium nitrate Understand the unique set of conditions necessary for the explosive decomposition of ammonium nitrate
    • How advanced blast techniques can be used to determine the quantity of ammonium nitrate that likely detonated during the blast How advanced blast techniques can be used to determine the quantity of ammonium nitrate that likely detonated during the blast

  • Oil & Gas

    Propane safety: Investigation findings and lessons learned in the 2014 Philadelphia Food Truck explosion

    Oil & Gas

    Propane safety: Investigation findings and lessons learned in the 2014 Philadelphia Food Truck explosion

    What you will learn

    • The results of the investigation into the cause and origin of the incident. The results of the investigation into the cause and origin of the incident.
    • The safety-critical design features and processes in the propane industry that must be in place to ensure the safe use and filling of propane cylinders. The safety-critical design features and processes in the propane industry that must be in place to ensure the safe use and filling of propane cylinders.

  • Dust in process industries

    Investigation findings and lessons learned in the 2014 Georgia Pacific Corrigan Facility fire and explosion

    Dust in process industries

    Investigation findings and lessons learned in the 2014 Georgia Pacific Corrigan Facility fire and explosion

    What you will learn

    • The proximate causes of the incident as well as key root causes that led to the explosion. The proximate causes of the incident as well as key root causes that led to the explosion.
    • Lessons learned from the key findings of the incident. Lessons learned from the key findings of the incident.
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