Petrochemical EHS & Process Safety Management Software

Unify petrochemical process safety, hydrocarbon releases, critical safeguards, compliance, and corrective actions in one connected platform.

Connect process events, PHA recommendations, Management of Change, mechanical-integrity findings, permit-to-work activities, hydrocarbon exposures, environmental releases, and corrective actions to the specific site, process unit, equipment, hydrocarbon stream, and operating condition.

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From first deviation to verified closure

Connect Petrochemical Process Safety From the First Event to Verified Closure

Petrochemical operations combine flammable hydrocarbons, toxic substances, high-temperature processing, elevated pressure, fired equipment, rotating machinery, complex reactions, process piping, relief systems, and safety-critical safeguards.

A hydrocarbon release, furnace upset, compressor trip, reactor excursion, relief-device activation, MOC gap, overdue PHA recommendation, or integrity finding can develop into a significant process-safety event if controls are not identified, corrected, and verified.

DEXUR connects each event with its process unit, equipment, operating conditions, investigation, responsible owner, corrective action, safeguard verification, and recurrence history.

  1. 01

    Identify

    Capture releases, excursions, fires, integrity findings, safeguard gaps, PHA actions, permit deviations, exposures, and environmental events.

  2. 02

    Investigate

    Connect the event to process unit, equipment, hydrocarbon stream, operating mode, alarms, interlocks, and contributing factors.

  3. 03

    Assess

    Evaluate flammability, toxicity, pressure, escalation potential, exposure, process consequence, and environmental impact.

  4. 04

    Prioritize

    Focus on high-consequence releases, safeguard weaknesses, overdue PHA actions, repeat deviations, and safety-critical findings.

  5. 05

    Assign

    Assign Process Safety, Operations, Engineering, Reliability, Maintenance, Environmental, or EHS ownership.

  6. 06

    Correct & Verify

    Track repairs, safeguard improvements, operating changes, MOC actions, and verify the control before closure.

One connected petrochemical process-safety platform

Manage Petrochemical EHS & Process Safety in One Platform

01 / LOSS OF CONTAINMENT

Hydrocarbon Release & Process Safety Event Management

Connect every release to its process unit, equipment, material, and operating condition.

Centralize ethylene, propylene, LPG, hydrogen, hydrogen sulfide, benzene, aromatic, and hydrocarbon-vapor releases alongside pump seal leaks, compressor seal failures, valve and flange leaks, piping failures, tank releases, and loading/unloading events.

  • Capture quantity released, hydrocarbon stream, equipment tag, immediate isolation, investigation, root cause, corrective action, and verification.
  • Connect flash fires, pool fires, jet fires, vapor-cloud events, explosions, and process near misses to the same process context.
  • Analyze recurring loss-of-containment events by unit, equipment class, stream, and operating condition.
02 / PROCESS UPSETS

Reactor, Furnace & Fractionation Process Safety

Turn abnormal operating conditions into traceable process-safety actions.

Track reactor temperature and pressure excursions, furnace trips and tube findings, column overpressure, distillation instability, compressor trips, feed disturbances, loss of cooling or steam, instrument-air interruptions, emergency shutdown activation, and abnormal flaring.

  • Connect deviations to unit, equipment, temperature, pressure, flow, alarms, interlocks, and operating mode.
  • Review safeguard performance and contributing conditions before assigning corrective actions.
  • Compare recurring excursions across similar reactors, furnaces, compressors, and process units.
03 / PHA & CRITICAL SAFEGUARDS

Petrochemical PHA, HAZOP & Safeguard Management

Connect hazard studies, recommendations, safeguards, and verification.

Manage Process Hazard Analysis, HAZOP nodes, initiating causes, consequences, existing safeguards, LOPA recommendations where applicable, safety-instrumented functions, alarms, relief systems, emergency shutdown systems, recommendation status, and safeguard verification.

  • Link each recommendation to its process node, hazard scenario, cause, consequence, safeguard, owner, and due date.
  • Track overdue recommendations and repeated safeguard weaknesses across units.
  • Verify completed actions against the equipment, control, alarm, interlock, or procedure affected.
04 / MANAGEMENT OF CHANGE

Petrochemical Management of Change & Pre-Startup Safety

Control process risk when feedstocks, chemistry, equipment, controls, or operating limits change.

Connect proposed changes to technical review, process-safety/PHA review, documentation updates, approval, training, Pre-Startup Safety Review, startup, and effectiveness verification.

  • Track changes to feedstocks, catalysts, process chemistry, piping, equipment, operating limits, control logic, alarms, interlocks, relief systems, utilities, procedures, and unit configuration.
  • Identify incomplete MOCs before startup and maintain evidence of required reviews and training.
  • Monitor whether changed processes create recurring deviations or new safeguard findings.
05 / MECHANICAL INTEGRITY

Petrochemical Equipment & Asset Integrity Findings

Keep safety-critical equipment findings connected to process risk.

Manage integrity findings involving reactors, fired heaters, cracker furnaces, distillation columns, pressure vessels, storage tanks, heat exchangers, compressors, pumps, piping, valves, relief devices, flare systems, instrumentation, alarms, interlocks, and emergency shutdown systems.

  • Connect each finding to the equipment tag, condition, process-risk priority, and Reliability or Maintenance owner.
  • Track repair, replacement, functional verification, and closure evidence.
  • Identify repeat integrity findings across similar equipment classes and sites.
06 / CONTROL OF WORK

Petrochemical Permit-to-Work & Turnaround Safety

Connect high-risk maintenance work to surrounding hydrocarbon and energy hazards.

Track hot work, line opening and breaking, confined-space and vessel entry, energy isolation, excavation, work at height, hydrocarbon equipment opening, turnaround maintenance, and contractor work.

  • Review process-unit, equipment, hydrocarbon, and energy hazards before work execution.
  • Connect isolation, gas testing, permit controls, restoration, and verification to the work record.
  • Analyze repeated permit deviations and turnaround findings by unit, activity, and responsible team.

See the patterns behind petrochemical process-safety events

See Where Risk Is Concentrating Across Your Petrochemical Operations

DEXUR connects individual process-event review with visibility across process units, equipment, hydrocarbon streams, critical safeguards, operating conditions, and corrective actions.

Teams can identify recurring loss-of-containment events, reactor and furnace excursions, compressor or pump seal failures, relief-device activations, overdue PHA/HAZOP actions, incomplete MOCs, repeat integrity findings, permit deviations, exposure concerns, and environmental releases.

Find Answers to Petrochemical Process-Safety Questions

  • Which process units have recurring loss-of-containment events?
  • Which reactors show repeated temperature or pressure excursions?
  • Which furnaces have recurring trip, flame, tube, or operating-condition findings?
  • Which compressors, pumps, valves, or flanges generate recurring hydrocarbon leaks?
  • Which tanks show repeated overfill, integrity, or containment concerns?
  • Which relief devices and flare events recur after previous corrective actions?
  • Which PHA or HAZOP recommendations remain overdue?
  • Which critical safeguards repeatedly fail testing or verification?
  • Which MOCs remain incomplete before startup?
  • Which line-opening, hot-work, or confined-space tasks show repeated permit deviations?
  • Which process areas show recurring benzene or hydrocarbon exposure concerns?
  • Which hazards return after corrective actions have been verified?

Measure the activities behind process-safety performance

Track the Activities Behind Petrochemical EHS & Process Safety Performance

Monitor leading process-safety controls and recurrence—not only the number of incidents.

KPI What It Helps You Monitor
API RP 754 Tier 1 & Tier 2 Process Safety Event Rate Tracks higher- and lower-consequence process-safety events and provides visibility into significant loss of containment, fire, explosion, and hazardous-release trends.
Loss of Primary Containment & Hydrocarbon Release Recurrence Rate Tracks releases from piping, vessels, tanks, pumps, compressors, transfer systems, and recurring hydrocarbon services.
Reactor / Process Excursion Rate Tracks recurring temperature, pressure, flow, level, reaction-control, and operating-condition excursions across process units.
PHA / HAZOP Recommendation Closure Rate Measures completion and verification of process-hazard-analysis and HAZOP actions, including overdue recommendations.
Management of Change & PSSR Completion Rate Tracks whether process changes complete technical review, safety review, documentation, training, approval, and pre-startup verification.
Mechanical Integrity Repeat Finding Rate Identifies recurring integrity issues involving pressure vessels, piping, tanks, pumps, compressors, fired equipment, and other safety-critical assets.
Critical Safeguard Verification Rate Measures successful testing and verification of alarms, trips, interlocks, relief systems, and emergency shutdown functions.
Permit-to-Work Deviation Rate Tracks deviations involving line opening, hot work, confined-space entry, energy isolation, hydrocarbon equipment opening, and turnaround activities.
Flaring & Fired-Equipment Finding Rate Tracks abnormal or recurring flaring, furnace trips, tube findings, burner or flame issues, and fired-equipment safeguard concerns.
Benzene / Hydrocarbon Exposure Finding Rate Tracks occupational exposure concerns in process units, tank farms, loading areas, sampling points, and maintenance activities.
Corrective Action Effectiveness Rate Measures whether implemented process-safety actions prevent recurrence after verification and closure.

Review these indicators by process unit, equipment class, hydrocarbon stream, operating condition, and site to distinguish isolated events from recurring process-safety patterns.

Every site. Every unit. One connected process-safety view.

Real-Time Visibility Across Petrochemical Operations

Connect process-safety information from enterprise leadership to petrochemical sites, process units, equipment, hydrocarbon streams, operating modes, safeguards, and corrective actions.

Corporate Process Safety & EHS Leaders

Compare API RP 754 performance, hydrocarbon-release trends, process-unit risk, PHA recommendation status, MOC performance, mechanical-integrity trends, flaring, environmental events, and corrective-action effectiveness across sites.

Site Process Safety & EHS Managers

Monitor process-safety events, PHA/HAZOP actions, MOC, PSSR, permit-to-work deviations, hydrocarbon exposure, critical safeguards, and high-risk corrective actions at the site and unit level.

Operations Managers

See unit-level deviations, reactor and furnace findings, compressor trips, relief-device activity, flare events, alarm/interlock issues, and operating actions tied to specific process conditions.

Reliability & Maintenance Teams

Track compressors, pumps, furnaces, reactors, pressure vessels, tanks, process piping, relief devices, safety-critical equipment, and integrity actions awaiting verification.

Organization

  1. Enterprise
  2. Region
  3. Petrochemical Site

Operations

  1. Plant / Process Unit
  2. Process Area
  3. Reactor / Furnace / Column / Compressor / Tank / Piping / Equipment
  4. Process Stream / Operating Mode

Follow-Through

  1. Incident / PHA / MOC / Inspection / Finding
  2. Investigation
  3. Corrective Action
  4. Verification

One connected petrochemical process-safety record

One Process Event. One Connected Record. One View of Petrochemical Risk.

Petrochemical process-safety information can be distributed across PHA studies, HAZOP worksheets, MOC systems, mechanical-integrity databases, permit systems, shift records, inspection forms, incident reports, environmental systems, turnaround records, and corrective-action trackers. DEXUR connects the complete petrochemical lifecycle.

Process Context

Connect events to the site, process unit, process area, equipment, hydrocarbon stream, operating mode, and conditions involved.

Critical Safeguards

Connect PHA, HAZOP, MOC, mechanical-integrity, safeguard, and PSSR findings to accountable owners and verification.

Corrective Action Accountability

Track Operations, Engineering, Reliability, Maintenance, Process Safety, Environmental, and EHS actions through verified closure.

Enterprise Process-Safety Reporting

Move from individual hydrocarbon releases and process deviations to connected KPI, recurrence, and API RP 754 visibility across sites.