Hazard Navigator, industry by industry.
Hazard Navigator reads the records a site already holds — hazard studies, drawings, change records and incident history — and models the site as the process it is. Each industry below shows what it covers, where studies tend to strain, and a data sheet to download.
Downstream & refining
A refinery is not a fleet of similar sites but one deeply interconnected process with thousands of study rows. Hazard Navigator models it unit by unit, across the process blocks below.
- Crude & vacuum distillation
- Conversion units
- Hydroprocessing & hydrogen
- Light ends, treating & sulfur
- Tank farm, blending & movements
- Utilities, relief & flare
One site, thousands of rows
A full revalidation is a multi-month program across dozens of units. Effort goes into rebuilding context that already exists in the documentation.
The five-year clock
The question a revalidation has to answer is what changed since the last study — not whether the analysis can be redone from scratch on the cycle.
Change arrives in waves
Turnarounds concentrate modifications into bursts. The backlog of changes needing hazard review spikes exactly when engineering attention is scarcest.
Midstream oil & gas
Midstream assets are archetypal, which is what makes a fleet tractable. Hazard Navigator models a site as the process it is, across the facility classes below.
- Gathering & compression
- Gas treating & conditioning
- NGL recovery & fractionation
- Metering, regulation & custody transfer
- Storage & liquids terminals
- Pipeline & pump stations
Repeating assets
Compressor banks of near-identical units, and stations built to one pattern site after site. Study effort does not repeat unless something carries it across.
Distributed record
Studies in PHA software, drawings in a document system, changes and incidents elsewhere again. Hazard Navigator reads all four and resolves them against one another.
Protection gets defeated
Shutdowns and detection are bypassed for starts, testing and maintenance. Whether that is tolerable turns on what else covers the scenario — a question about the study, not the device.
Upstream oil & gas
Upstream assets range from a wellpad that fits on an acre to a manned offshore facility with a formal safety case. Hazard Navigator models each as the process it is, across the facility classes below.
- Wellpads & wellheads
- Tank batteries & separation
- Central processing & compression
- Offshore production facilities
- Water handling & injection
- Gathering & field infrastructure
More sites than review cycles
A fleet is hundreds or thousands of locations against a handful of process safety engineers. Coverage is decided by what can be reached, not by where the risk sits.
Nobody is standing there
Most locations are unmanned and remote. Detection, automatic shutdown and response time are not supporting details — they are the safeguards the scenario depends on.
Standard design, field-modified
Facilities are built to a pattern and then changed locally. The study describes the design; the drawings, changes and incidents describe what is actually standing there.
Chemicals
A chemical plant is defined by what it makes and how the chemistry behaves, not only by its equipment. Hazard Navigator models the unit as the process it is, across the facility classes below.
- Batch reaction & multi-purpose plant
- Continuous reaction & catalysis
- Separation & purification
- Solvent & raw material storage
- Utilities & thermal systems
- Loading, transfer & waste treatment
The plant changes faster than the study
Multi-purpose assets run campaigns, recipes are revised, and equipment is re-piped between products. Each change can invalidate study rows written for a different chemistry in the same vessel.
Hazard lives in the procedure
In batch operation the deviation is often a step — charged in the wrong order, held too long, cooled too late. That hazard is invisible to an analysis anchored only to equipment and line numbers.
Reactivity crosses the boundary
Incompatibility is a property of a pair, not of a vessel. Screening it means reading the inventory, the segregation and the transfer paths together, across units that separate studies treat independently.
Biotech & pharmaceutical
Pharmaceutical sites concentrate several distinct hazard types into a small footprint, often in the same building. Hazard Navigator models each area as the process it is, across the classes below.
- API & small-molecule synthesis
- Biologics & fermentation
- Solvent storage & recovery
- Containment & potent compounds
- Clean utilities & cryogenics
- Waste, effluent & abatement
Multi-purpose by design
The same suite makes a different product next campaign. A study written for the previous chemistry in the same equipment may no longer describe what runs there.
Change control already exists
Under GMP the change record is rigorous and complete. The gap is not the process — it is that nothing reads that record against the hazard studies it may affect.
Scale-up moves the hazard
Thermal behavior does not scale linearly from laboratory to pilot to commercial. Assumptions that held at one scale need revisiting at the next.
Cross-industry
Outside the process industries proper, facilities have little in common with one another — but their hazards do. Hazard Navigator is organized around the hazard rather than the sector, which is what lets one model serve a plant no vendor has built a template for.
Where it applies: Food and beverage, pulp and paper, metals, semiconductor, water treatment, power, fertilizer and agrochemicals, coatings.
- Flammable liquids & vapor
- Toxic gas & inhalation
- Ammonia refrigeration
- Combustible dust
- Exothermic & reactive processes
- Pressure & thermal systems
Uneven coverage
Regulated parts of a site carry formal studies; the rest may carry little. The first question is usually what is covered, and the honest answer is rarely uniform.
Broad scope, small team
One EHS or process safety lead often covers several unrelated hazard classes, each with its own body of good practice and its own documentation.
Records written for the plant
Drawings, change records and incident logs were written to run and maintain the facility, not to feed an analysis. Making them analysable is the work.
Prove it on your data.
Bring the work that’s already due — a unit up for revalidation, or your open MOC backlog. We’ll run the reconciliation read-only and show you what it finds. Ready to move into production if the pilot earns it.
Read-only, evidence-linked, and human-approved — your data stays yours. From a single unit, the economics scale by hazard exposure, not headcount.