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

Safety Integrity Level determination is a well-understood step in functional safety practice - it establishes the target...
15/06/2026

Safety Integrity Level determination is a well-understood step in functional safety practice - it establishes the target reliability that a Safety Instrumented Function must achieve in order to reduce process risk to a tolerable level. What is less consistently understood is that SIL determination establishes a target, not a result. SIL verification is the separate, equally important activity that demonstrates through calculation and analysis whether the designed Safety Instrumented System actually meets that target - and it must be completed before the SIS can be considered fit for purpose.

SIL verification involves a quantitative assessment of the Probability of Failure on Demand or the failure frequency of each Safety Instrumented Function, accounting for the reliability data of every component in the safety loop, the diagnostic coverage of the system, the proof test interval, and the architecture. Many organisations treat SIL verification as a confirmatory exercise late in the design process, only to discover that the achieved integrity falls short of the target. At that stage, the options - redesigning the architecture, changing component selection, or shortening proof test intervals - can all carry significant cost or operational impact.

Projex Solutions supports clients through the full functional safety lifecycle, including SIL determination via LOPA or risk graph methods and SIL verification using recognised calculation methodologies. Our engineers work across the design phase to ensure that SIS architecture and component selection are aligned with the determined SIL target before the verification calculation is performed, reducing the risk of late-stage redesign. We also support SIL verification reviews for existing systems where proof test data, component changes, or revised operating conditions may have affected the calculated integrity.

If you are designing a new Safety Instrumented System or reviewing the integrity of an existing one, talk to Projex Solutions about how we can support you.

A Hazardous Area Classification (HAC) report is the document that defines which areas of a process site present a risk o...
14/06/2026

A Hazardous Area Classification (HAC) report is the document that defines which areas of a process site present a risk of explosive atmosphere formation. Wherever flammable gases, vapours, mists, or combustible dusts are handled, there is a potential for an explosive atmosphere to form if those substances escape into the surrounding environment. The HAC report identifies those areas, classifies them into zones based on the likelihood and duration of explosive atmosphere formation, and establishes the boundaries within which special controls apply.

The zone classification defined in a HAC report directly determines what equipment can be installed and operated in each area. Electrical and mechanical equipment used in classified zones must be appropriate for the zone in which it is installed - a requirement under ATEX regulations. Getting the classification wrong, or relying on an out-of-date report that does not reflect current site conditions, can mean equipment is incorrectly specified, maintenance activities are carried out without adequate controls, and the site is exposed to both operational and legal risk.

Projex Solutions produces HAC reports for process manufacturing and COMAH sites, drawing on detailed knowledge of site processes, substance properties, and recognised classification standards. Our assessments consider all relevant release sources, define zone extents and types, and are accompanied by Hazardous Area drawings that give operations and maintenance teams a clear, practical reference for working safely in classified areas. We also review and update existing HAC reports where plant modifications, process changes, or regulatory updates have created gaps in the current classification.

If you need a new HAC report or want an independent review of your existing hazardous area classification, talk to Projex Solutions about how we can support you.

Stakeholder and communication management is frequently treated as a soft discipline in capital project delivery - import...
13/06/2026

Stakeholder and communication management is frequently treated as a soft discipline in capital project delivery - important in principle, but secondary to the technical and commercial priorities that drive day-to-day project activity. In regulated process manufacturing, this perception carries real risk. Capital projects on operating sites involve a wide range of stakeholders - operations, maintenance, HSE, finance, regulatory bodies, and executive sponsors - each with different information requirements, different approval authority, and different levels of tolerance for uncertainty. When communication is managed informally, critical information reaches the wrong people too late, or the right people not at all.

The practical consequence of poor stakeholder management is delay. Decisions that should be made in days extend to weeks because the right stakeholders were not brought into the process at the right stage. Design freeze is missed because operations has not reviewed and approved the scope. Procurement cannot proceed because finance has not been kept informed of the commercial implications. HAZOP findings are not actioned because the accountable stakeholder was not present at the study. Each individual delay looks manageable in isolation - collectively they erode programme performance and consume contingency that was held for genuinely unpredictable events.

Projex Solutions embeds structured stakeholder and communication management within its project delivery approach, developing communication plans that map information requirements to stakeholder groups and establish clear processes for decision-making, approval, and escalation. On complex projects with multiple stakeholder groups and regulatory obligations, we provide the project governance framework that ensures the right people are engaged at the right time with information they can act on. This is not an administrative function - it is a project delivery discipline that directly affects the speed and quality of decisions throughout the project lifecycle.

If you have a capital project where stakeholder complexity is creating coordination challenges, talk to Projex Solutions about how we can support you.

Over the past week, we’ve been pleased to welcome Hudson Ritchie to the Projex Solutions Brighouse office for his work e...
12/06/2026

Over the past week, we’ve been pleased to welcome Hudson Ritchie to the Projex Solutions Brighouse office for his work experience placement.

Hudson currently attends North Halifax Grammar School, where he is studying Computer Science, Design and Technology, Triple Sciences and Geography. Outside of school, he enjoys gaming, art, creating things and spending time with friends.

Hudson also has a clear ambition for the future, having wanted to become a game developer since he was around 8 years old. It has been great to hear about his interests, enthusiasm for technology and creative mindset during his time with the team.

At Projex Solutions, we are always happy to support opportunities for young people and help provide an insight into the workplace and industry. Encouraging interest in STEM subjects is incredibly important, not only for individual development but also for the future of engineering, technology and innovation across the UK.

Work experience placements are a valuable way for students to gain confidence, explore potential career paths and see how the subjects they study in school connect to real-world industries and projects.

A big thank you to Hudson for spending the week with us. Everyone at Projex Solutions would like to wish him the very best with his studies and future ambitions.

Concept screening and design is the phase in a capital project where technical options are identified, evaluated, and na...
12/06/2026

Concept screening and design is the phase in a capital project where technical options are identified, evaluated, and narrowed down to a preferred approach before significant engineering investment is committed. It is the stage where the fundamental questions about how a project will be delivered are answered - what process route will be used, how the new scope will interface with existing plant, what the major equipment configuration will be, and what constraints will define the boundaries of the detailed design. These are the decisions that shape everything that follows, and they are most cost-effective to make thoroughly at concept stage.

The consequence of inadequate concept screening is a design that reflects the first technically feasible option rather than the best technically justified one. Projects that enter FEED or detailed design without a properly evaluated concept carry unresolved risk in their technical basis. Alternative process routes that might have offered simpler operation, better safety characteristics, or lower capital cost have not been considered. Interface options that might have reduced construction complexity or regulatory risk were not explored. The project proceeds with an approach that was never tested against alternatives - and the assumptions embedded in that approach become progressively harder to revisit as the design matures.

Projex Solutions supports clients through concept screening and design development, providing multi-discipline engineering input to evaluate technical options against process, safety, constructability, and regulatory criteria. Our engineers develop concept designs to a level of definition that supports meaningful comparison - including outline process configurations, indicative equipment arrangements, and a preliminary assessment of the safety and regulatory implications of each option. We provide clients with a clear, technically grounded basis for selecting the preferred concept before committing to FEED or detailed engineering expenditure.

If you are developing a capital project and want to ensure the concept is properly evaluated before FEED begins, talk to Projex Solutions about how we can support you.

With the World Cup starting today, excitement is building as England prepares to compete on the biggest stage in footbal...
11/06/2026

With the World Cup starting today, excitement is building as England prepares to compete on the biggest stage in football.

While the tournament is all about what happens on the pitch, it is also a reminder of the importance of teamwork, communication, trust and supporting one another, values that are just as important within engineering and project delivery.

At Projex Solutions, we know that successful projects are never the result of one individual. They come from people working together, sharing knowledge, supporting each other and combining different strengths towards a common goal.

The World Cup is also a fantastic celebration of diversity, bringing together people, cultures and communities from across the world through a shared passion for the game. That sense of inclusion and togetherness is something we value strongly within our own team and across the industries we support.

There will no doubt be plenty of football conversations, predictions and friendly debates around the office over the coming weeks, but for now, everyone at Projex Solutions would like to wish the England team the very best for the tournament ahead.

Come on England!

Engineering due diligence is the structured assessment of the technical condition, compliance status, and risk profile o...
10/06/2026

Engineering due diligence is the structured assessment of the technical condition, compliance status, and risk profile of an asset, facility, or engineering business prior to acquisition, investment, or significant capital commitment. In process manufacturing and regulated industry, the technical complexity of assets means that the gap between what is visible during a commercial transaction and what is actually present in the engineering record can be substantial. Decisions made without adequate technical due diligence can result in the acquirer inheriting liabilities that were known to the vendor, or risks that neither party recognised because they were never formally assessed.

The most significant engineering risks in an acquisition or investment context are rarely the ones that are disclosed. They tend to be embedded in the condition of ageing plant, gaps in the safety case, outstanding regulatory actions, non-compliant modifications that were never documented, and a hazardous area classification that has not been reviewed since the original installation. These issues do not resolve themselves when ownership changes. They become the new owner's problem - often surfacing during the first major project, the first regulatory inspection, or the first insurance renewal after the transaction is complete.

Projex Solutions provides engineering due diligence support to clients considering acquisitions, investments, or significant capital commitments in process manufacturing assets. Our engineers carry out structured technical assessments that examine process safety documentation, regulatory compliance status, plant condition, engineering records, and the quality of the existing design basis. We provide clients with a clear, independent view of what they are acquiring - including a realistic assessment of the capital investment required to bring the asset to a compliant, maintainable condition - before commercial commitments are made.

If you are considering an acquisition or investment in a process manufacturing asset and want independent engineering input before you commit, talk to Projex Solutions about how we can support you.

Engineering Procurement Construction Management is a delivery model built around integrated responsibility. Under EPCM, ...
09/06/2026

Engineering Procurement Construction Management is a delivery model built around integrated responsibility. Under EPCM, a single partner takes accountability for developing the engineering, managing the procurement supply chain, and overseeing construction - maintaining a consistent technical thread from design through to site completion. The model exists because the alternative - engaging separate organisations for each function and attempting to coordinate them through contractual interfaces - creates accountability gaps that are difficult to close once a project is under pressure.

The failure mode of fragmented delivery is well documented and consistently repeated. Engineering is completed by one party, procurement managed by another, and construction overseen by a third - each working to their own programme, their own commercial interests, and their own interpretation of the technical scope. When a procurement decision conflicts with an engineering requirement, or when a construction issue requires an engineering response, the coordination that should happen quickly across an integrated team instead becomes a cross-contractual negotiation. The project absorbs the time and cost while accountability remains disputed.

Projex Solutions operates as an EPCM partner for process manufacturing and regulated industry clients, providing multi-discipline engineering, procurement management, and construction oversight within a single, accountable scope. Our EPCM model is structured around maintaining engineering authority throughout the project - ensuring that procurement decisions are technically led and that construction is executed against a design that the engineering team stands behind. For clients operating in regulated environments, this integrated accountability is not just commercially efficient - it is essential for demonstrating that the completed facility meets its design intent and regulatory obligations.

If you are planning a capital project and want a single engineering partner to carry the accountability from design to completion, talk to Projex Solutions about how we can support you.

The process design basis is the foundational technical document that establishes the premises, parameters, and constrain...
08/06/2026

The process design basis is the foundational technical document that establishes the premises, parameters, and constraints within which all engineering design must be carried out. It records the process conditions - flows, temperatures, pressures, compositions - the design margins applied, the operating philosophy, the regulatory and standards framework, and the key assumptions that underpin the design. On a well-run capital project, the design basis is the technical reference that allows every engineer, across every discipline, to make decisions that are consistent with each other and with the project intent.

When the design basis is absent, incomplete, or not kept current as the design develops, the consequences work their way through every discipline. Process engineers design equipment to conditions that mechanical engineers do not recognise. Instrumentation is specified against process data that has been superseded. Safety studies assess a design that does not reflect current assumptions. Each discipline produces technically sound work that does not fully align with the others, and the integration problems that result are discovered progressively through design reviews, HAZOP studies, and ultimately on site. The cost of resolving misalignment increases with each stage of the project.

Projex Solutions develops process design bases for capital projects from feasibility through to detailed engineering, providing clients with a technically rigorous foundation that supports consistent decision-making across disciplines. Our process engineers work alongside the wider project team to ensure that the design basis reflects actual project requirements, is updated as the design evolves, and is communicated clearly to all parties. We also carry out process calculations - mass and energy balances, equipment sizing, hydraulic studies, and relief system analyses - that translate the design basis into the technical inputs that engineering disciplines require.

If you are developing a capital project and want to ensure the design basis is properly established before detailed engineering proceeds, talk to Projex Solutions about how we can support you.

Low voltage power distribution is the foundation on which every piece of electrical equipment in an industrial facility ...
07/06/2026

Low voltage power distribution is the foundation on which every piece of electrical equipment in an industrial facility depends. In process manufacturing, where production lines, control systems, safety instrumented systems, and utilities all draw from a common electrical infrastructure, the design and management of LV distribution directly affects plant reliability, operational flexibility, and the ability to accommodate future modifications. It is a discipline that sits at the interface between engineering design and site operations, and its condition and capacity are often less well understood than the process equipment it serves.

On brownfield sites, the most common source of LV distribution risk is the assumption of adequate capacity. Equipment is added, loads increase, and the electrical infrastructure accumulates changes that were each individually assessed but never reviewed as a whole. The result can be a distribution system that is operating close to its design limits in ways that are not immediately apparent from the existing documentation. When a capital project introduces new electrical loads to such a site - whether new process equipment, upgraded control systems, or additional utilities - the capacity constraints surface as a design problem that was not anticipated in the project scope and must be resolved at additional cost.

Projex Solutions provides LV power distribution design services as part of our EC&I engineering capability, covering load analysis, distribution board design, sizing calculations, and single-line diagram development for new and modified facilities. On brownfield projects, we carry out electrical capacity assessments early in the design process to identify constraints before they become programme issues. Our engineers design distribution systems that meet current requirements while accommodating realistic future demands, and we produce documentation that gives operations and maintenance teams a clear reference for the installed infrastructure.

If you have a capital project that will introduce new electrical loads to an existing facility, talk to Projex Solutions about how we can support you.

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

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