COMAH Compliance Through Bespoke Safety Systems
For COMAH operators, compliance is not achieved through documentation alone. It depends on being able to demonstrate that major accident hazards are understood, controlled, monitored, and reduced so far as is reasonably practicable.
The Control of Major Accident Hazards Regulations 2015 require operators to prevent major accidents involving dangerous substances and limit the consequences to people and the environment. For upper-tier establishments, this is supported through a detailed safety report; for lower-tier sites, through a Major Accident Prevention Policy and appropriate management systems.
In both cases, engineered safety systems are a critical part of the compliance evidence base — and they need to be designed around the specific risks, processes, and operating environment of each site.
Safety Systems Designed Around Your Site
No two COMAH establishments are exactly the same. The hazards, process conditions, legacy infrastructure, operating philosophy, environmental factors, and regulatory expectations can vary significantly from site to site.
That is why a standard, off-the-shelf approach is rarely enough.
Proeon works with operators to design and deliver bespoke safety and control systems aligned with the specific requirements of their facility. Whether the site requires a new safety system, an upgrade to ageing infrastructure, integration with existing control systems, or support closing out regulatory actions, Proeon can tailor the solution to suit the application.
This can include:
Emergency shutdown systems
Fire and gas detection systems
Process shutdown systems
Burner management systems
High-integrity protection systems
Alarm and monitoring systems
Remote isolation and blowdown interfaces
Safety PLC and control system integration
Legacy system upgrades and migration
Each solution can be engineered to reflect the site’s hazard profile, operational constraints, safety lifecycle requirements, and long-term maintenance strategy.
Supporting the COMAH Evidence Base
Where safety systems are credited within hazard studies, LOPA, bowtie analysis, or safety reports, their performance must be clearly defined and demonstrable.
Proeon can help operators build this evidence into the system design by supporting:
Cause and effect development
Functional design specifications
Safety system architecture
Input/output and field device selection
Control and protection layer separation
Proof test and maintenance considerations
FAT, SAT, commissioning, and validation
Documentation and configuration control
This gives operators a clearer link between the identified major accident hazard and the engineered safeguard intended to control or mitigate it.
For COMAH sites, that traceability is essential. It helps demonstrate that safety-critical systems are not only installed, but capable of performing their intended function when required.
Addressing Legacy and Brownfield Challenges
Many COMAH operators are managing ageing assets, legacy control systems, and facilities that have evolved over many years. This can create challenges where documentation, system architecture, and current operating practice no longer fully align.
Common issues include:
Outdated cause and effect documentation
Ageing fire and gas infrastructure
Obsolete safety-critical components
Limited spares availability
Poor alarm rationalisation
Incomplete proof test records
Unclear bypass or inhibit management
Modifications not fully reflected in system documentation
Difficulty integrating new safety technology with existing systems
Proeon can support these environments by developing practical, site-specific upgrade and migration strategies. This allows operators to improve safety system performance and maintain compliance without unnecessary disruption to operations.
Bespoke Engineering From Design Through to Lifecycle Support
Proeon’s support does not stop at system design. We can work with COMAH operators throughout the full safety system lifecycle, from initial concept and specification through to installation, commissioning, testing, maintenance, and future upgrades.
Our engineers can help ensure systems are:
Correctly specified for the site’s major accident hazard scenarios
Designed with appropriate independence, reliability, and diagnostics
Integrated with existing plant and control infrastructure
Tested and validated against functional requirements
Supported with clear technical documentation
Maintained and managed through future modifications
This lifecycle approach helps operators keep safety systems aligned with the site’s evolving risk profile, asset condition, and regulatory expectations.
How Proeon Can Help
Proeon designs, delivers, upgrades, and supports safety and control systems for high-hazard industrial environments. Our strength lies in developing bespoke solutions that are engineered around the needs of each site rather than forcing operators into a generic system design.
Whether you are preparing for inspection, responding to regulatory findings, upgrading ageing infrastructure, improving safety report evidence, or replacing obsolete systems, Proeon can help deliver a solution that is technically robust, practical, and tailored to your operational requirements.
By aligning safety system engineering with the site’s major accident hazard profile, Proeon helps operators strengthen compliance, reduce risk, and protect people, assets, and the environment.