Projex Solutions Limited

Projex Solutions Limited Projex Solutions are leaders within a variety of highly regulated process manufacturing industries,

Formed in 2006, Projex Solutions has grown to a multi-disciplined team of highly experienced and skilled engineers across both our West Yorkshire & North East offices. Leaders within a variety of highly regulated process manufacturing industries, our team of experts can add value to your project team, offering a vast range of Engineering Consultancy, Engineering Design & Project Management service

s. Here at Projex Solutions we provide a service of engineering excellence, working upon a wide range of projects varying in both scope and scale; we are always prepared to undertake one off, small scale or difficult to implement contracts whilst working effectively to maintain costs and timeframes. We have fostered a culture of professionalism with our structured methodical approach, finding the solution that your business needs. Our mission is to continue to deliver first class design, development and project management solutions safely, utilising the latest technologies working with your team as your ultimate project partner. We are Projex Solutions: Your Engineering Procurement Construction & Management Partner (EPCM). Project Management
• Engineering Procurement Construction Management Package (EPCM)
• Framework Agreements for Engineering Support
• Contractual Agreements NEC3 or IChemE Forms of Contract
• Project Planning & Programme Development
• Procurement Scheduling & Management
• Construction Design Management (CDM)
◦Principal Contractor
◦Principal Designer

ATEX Compliance
• Hazardous Area Classification (HAC)
◦Compliance with EI15 (former IP15)
◦Compliance with IEC60079-10
• DSEAR Assessments
• CompEX
◦EX01-04 Inspections Gases & Vapours
◦EX05-06 Inspections Dusts, Fibres & Filings
◦EX11 Mechanical (MEIRA)
◦EX12 Application Designer
Engineering Consultancy – Plant/Process Support
• Feasibility Studies
• Front End Engineering Design (FEED)
• Detailed Engineering Design
• Compiling ITT Packages
Introduction to Projex Solutions

Our Services
• Upgrade of Plant/Process Optimisation
• Factory Layout, Logistics &/or Relocation
• User Requirement Specification (URS)
• Functional Design Specification (FDS)
• Factory Acceptance Test / Site Acceptance Test (FAT/SAT)
• Commissioning &/ Support (Wet/Dry)

Safety Studies
• Hazard Identification Study (HAZID)
• Hazard and Operability Study (HAZOP)
• Layers of Protection Analysis (LOPA)
• Functional Safety/SIL Studies
• Process Hazard Review (PHR)
• Process Safety Improvements
• Pressure Relief Stream Design

Engineering Design – Multi-disciplined Team
• Electrical, Control & Instrumentation Design
• Process & Safety Engineering Design
• Mechanical & Piping Engineering Design

Bulk storage of flammable liquids and gases looks static from the outside. It is not. Tank farms and storage vessels sit...
01/09/2026

Bulk storage of flammable liquids and gases looks static from the outside. It is not. Tank farms and storage vessels sit at the intersection of vapour behaviour, overfill protection, secondary containment, vent design, static control and emergency response, and every one of those needs to be right at the same time.

The recurring gaps are well documented. Overfill protection that is not independent of the primary level control. High-level trips that have never been proof-tested at the interval their SIL claim assumes. Bunds sized for the tank but not for firewater, or with penetrations that were never sealed after a modification. Vapour space and vent arrangements that no longer reflect the product actually being stored after a change of service. And hazardous area classification drawings that quietly went out of date the day the last pump was replaced.

Projex Solutions brings process safety and design engineering together on storage installations. That means DSEAR assessment and hazardous area classification with current zone drawings, HAZOP and LOPA of filling and transfer operations, SIL determination and verification for overfill protection, containment and CIRIA C736 review, and the mechanical and EC&I design to implement what the studies conclude. We work to the standards your regulator and insurer will measure you against.

If you are reviewing a tank farm, changing product service, or preparing for a COMAH or environmental inspection, talk to Projex Solutions.

It is the August bank holiday, and the Projex Solutions office is closed. For anyone working in process manufacturing, a...
31/08/2026

It is the August bank holiday, and the Projex Solutions office is closed. For anyone working in process manufacturing, a genuine long weekend is worth more than it looks on a calendar. Ours is an industry that runs on attention, and attention is a finite resource.

The work we do carries consequences. Hazard studies, safety cases, design reviews and site commissioning all depend on people who are alert enough to notice the detail that does not fit. Fatigue is a recognised performance-shaping factor in human factors assessment for exactly that reason. Tired engineers miss things, and on a live process site the things that get missed are rarely trivial. Protecting rest is not separate from protecting safety.

At Projex Solutions we plan our project resourcing around that reality rather than in spite of it. Realistic programmes, sensible workloads and clear handovers mean our engineers are not routinely running on empty, and our clients get better judgement as a result. It is also simply the right way to treat people.

To everyone spending today with family, out walking, or doing nothing at all, enjoy it. And to the shift teams keeping plants running safely through the bank holiday, thank you. Normal service resumes tomorrow at Projex Solutions.

Good process design is not the design that performs best on paper. It is the design that performs on a Tuesday afternoon...
30/08/2026

Good process design is not the design that performs best on paper. It is the design that performs on a Tuesday afternoon in February, with the raw material slightly off spec, one pump out for maintenance and a changeover due before the end of shift. The mass and energy balance is the starting point, not the answer.

Designs come unstuck at the edges of the envelope. Turndown is treated as an afterthought, so the plant runs badly at anything below nameplate. Hydraulics are sized for the design case only, and the system will not hold flow when a heat exchanger fouls. Cleaning, sampling, isolation and drainage are worked out during commissioning rather than during design, which is when the awkward retrofits, temporary hoses and workarounds start to accumulate. Every one of those workarounds is a future safety and quality problem.

Projex Solutions builds the process design basis around how the plant will actually be operated. That means mass and energy balances, hydraulic and relief calculations, equipment sizing and specification, P&ID development and line lists, all developed with operability, maintainability and cleaning in mind, and tested through structured design reviews and HAZOP. We ask the operations and maintenance questions early, while they are still design decisions rather than site problems.

If you are developing a new process, debottlenecking an existing one, or want an independent review of a design basis before it is committed, talk to Projex Solutions.

Equipment qualification exists to answer four questions in sequence. Was it designed to meet the requirement? Was it ins...
29/08/2026

Equipment qualification exists to answer four questions in sequence. Was it designed to meet the requirement? Was it installed as designed? Does it operate correctly across its full range? And does it perform consistently under real production conditions with real product? DQ, IQ, OQ and PQ only work as a chain. Break a link and the assurance the chain was supposed to provide is gone.

Most qualification failures are traceable back to the user requirements specification. If the URS is vague about operating envelope, cleanability, utility conditions or data integrity, then DQ has nothing firm to test the design against, and OQ acceptance criteria end up written to match whatever the equipment happens to do. The consequences appear later and cost more: extended commissioning, product on hold, deviation investigations, requalification after a change that was never properly assessed, and in the worst cases a batch loss on a line that was supposedly proven.

Projex Solutions supports equipment qualification end to end, starting with a URS that is specific and testable. We develop and execute DQ, IQ, OQ and PQ protocols, define acceptance criteria that reflect the actual process duty, manage vendor FAT and SAT interfaces, and maintain traceability from requirement to test result so the qualification package is coherent when it is reviewed. We also revalidate existing installations where documentation has drifted from the plant.

If you are qualifying new equipment, or need to bring an existing installation back to a defensible position, talk to Projex Solutions.

We are pleased to share that Hayder Abbas and Finley Cahill, both Process Engineers at Projex Solutions, have registered...
28/08/2026

We are pleased to share that Hayder Abbas and Finley Cahill, both Process Engineers at Projex Solutions, have registered as STEM Ambassadors through STEM Learning.

STEM Ambassadors are volunteers from science, technology, engineering and maths backgrounds who give their time to work with schools, colleges and community groups. The aim is straightforward: give young people a realistic picture of what an engineering career actually looks like, from people doing the job.

For Hayder, the draw was mentoring. "I want to help future generations in whatever way I can, particularly through mentoring. Everybody needs a mentor at some point, in every aspect of their life." He is hoping to support young people with guidance and interview preparation.

Finley sees it as a chance to offer a perspective that is still fresh. "As someone in the early stages of my engineering career, I can give a relatable view and use my recent experience to offer career advice that points people in the right direction." He is also keen to represent Projex and highlight the opportunities available here and across the wider industry.

Their involvement sits alongside the work we already do to support the next generation of engineers, including student work experience, our apprenticeship routes and our links with universities and professional institutions.

If your school, college or organisation is looking for engineers to support a STEM activity, get in touch with Projex Solutions.

Layer of Protection Analysis works on a simple premise: credit is only given to a safeguard that is genuinely independen...
27/08/2026

Layer of Protection Analysis works on a simple premise: credit is only given to a safeguard that is genuinely independent of the initiating event and of every other layer already claimed. That word, "independent", carries the entire weight of the method. Get it right and LOPA gives a defensible, semi-quantitative view of residual risk. Get it wrong and the study produces a comfortable number that does not describe the plant.

Common ground truth is where it breaks down. A high-level alarm and a high-high trip that share the same transmitter are one layer, not two. An operator response credited at a probability of failure on demand of 0.1 needs a clear, unambiguous indication, adequate time to act, and a procedure that is trained and actually followed. A relief device only counts if it is sized for the scenario being analysed, not merely present. Dual credit for the BPCS as both initiating cause and protective layer is a recurring finding in study reviews, and it quietly inflates the risk reduction claimed.

Projex Solutions facilitates LOPA as a disciplined extension of HAZOP rather than a paper follow-on. We test each candidate layer against the independence, effectiveness and auditability criteria, trace the instrumentation and utilities behind it, and carry the outcome through to SIL determination and verification so the required integrity is engineered rather than assumed. Where a layer does not stand up, we say so and set out the practical options.

If you are revalidating your LOPA studies or want an independent facilitator to test the layers you are relying on, talk to Projex Solutions.

In regulated process manufacturing, compliance is not a document exercise that sits alongside the plant. It is a propert...
26/08/2026

In regulated process manufacturing, compliance is not a document exercise that sits alongside the plant. It is a property of the plant itself. COMAH, DSEAR, PUWER, GMP and the Environmental Permitting Regulations all ultimately ask the same question: can you demonstrate that your process is designed, installed and operated so that the risks are understood and controlled? That demonstration is an engineering argument, and it only holds if the engineering behind it holds.

The gap usually shows up under scrutiny. A safety report cites protective measures that were never fully commissioned. A DSEAR file references zone drawings that no longer match the installed equipment. A validation package is signed off against a URS that quietly changed during procurement. None of these are paperwork errors. They are engineering gaps that paperwork was asked to cover, and inspectors, insurers and incident investigators are all increasingly good at finding them.

Projex Solutions works from the engineering upwards. We develop and verify the technical basis that compliance depends on: process design basis and calculations, P&IDs and hazardous area classification, HAZOP and LOPA studies, SIL determination and verification, and equipment qualification through DQ, IQ, OQ and PQ. We produce the evidence as a by-product of doing the engineering properly, so the documentation reflects the plant as it is actually built and operated rather than as it was once intended.

If you are preparing for an inspection, closing out actions from a regulatory review, or want an independent view of whether your technical basis stands up, talk to Projex Solutions.

Concept design looks inexpensive. A handful of engineers, some sketches and options, a few weeks of work. What is actual...
25/08/2026

Concept design looks inexpensive. A handful of engineers, some sketches and options, a few weeks of work. What is actually being decided is the shape of everything that follows: the process route, where the plant sits, how it is operated and maintained, and which hazards the project has just designed in for the next twenty years.

Errors made here do not stay small. A layout that leaves no maintenance access becomes a permanent operational cost. A process route chosen without testing its relief case becomes a safety problem discovered during detailed design. An undersized utility becomes the constraint that shows up at commissioning, when the plant will not reach rate and there is nothing left to adjust. The mistake was cheap to make and expensive to live with.

Projex Solutions treats concept design as engineering rather than sketching: options screened against real criteria, early process calculations to test feasibility, layouts checked for access and constructability, and hazards identified while changing direction still costs nothing.

If you have a project at concept stage, talk to Projex Solutions before the shape of it is fixed.

We're delighted to welcome Eoin Brady to Projex Solutions as an EC&I Design Engineer.Eoin grew up in Dubai before moving...
24/08/2026

We're delighted to welcome Eoin Brady to Projex Solutions as an EC&I Design Engineer.

Eoin grew up in Dubai before moving to the UK at 18 to study at Swansea, where he gained a BEng (Hons) in Electrical and Electronic Engineering. He then spent four years in the nuclear industry, based in Warrington, and joins us bringing that experience across into regulated process manufacturing. He is now based in Manchester and, in his own words, is slowly working his way north.

Away from work, Eoin follows football closely, supports Manchester United, and is a keen esports fan.

Here's what Eoin had to say about joining Projex Solutions:

"I have moved cities and countries more times than I can count. Since I've become part of the team at Projex Solutions I have never felt more at home. I hope I can repay that kindness by doing right by them and our clients. I have a lot to learn but I am excited to get the chance to do so alongside my colleagues at Projex Solutions."

We're excited to have you on board, Eoin - welcome to the Projex family!

Every capital project reaches the point where the schedule is under pressure and something has to give. It is at exactly...
23/08/2026

Every capital project reaches the point where the schedule is under pressure and something has to give. It is at exactly that moment that the character of a delivery partner becomes visible. The hazard study that gets deferred, the design check quietly skipped, the permit written to keep work moving - each buys back a day and puts it on account somewhere else.

On a regulated site that account is settled with interest. Studies completed after the design is fixed inform nothing. Modifications installed ahead of assessment become findings at the next inspection. And the risk that was accepted informally, under time pressure, by people who meant well, is the one that appears in the incident report.

As an EPCM partner, Projex Solutions holds engineering, procurement and construction management under one accountable team, which means the schedule and the safety case are managed by the same people rather than traded against each other. Where the programme is genuinely at risk we say so early, and we re-plan rather than quietly lowering the standard.

If you want a partner whose delivery you can trust under pressure, talk to Projex Solutions.

Address

St Pegs House, Thornhill Beck Lane
Brighouse
HD64AH

Opening Hours

Monday 8am - 5pm
Tuesday 8am - 5pm
Wednesday 8am - 5pm
Thursday 8am - 5pm
Friday 8am - 5pm

Telephone

+44 1484 711333

Website

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