The Challange
A leading research and development organisation had experienced significant growth, supporting both academic and commercial clients on a global scale. With more than 3,500 systems installed worldwide, the organisation had outgrown its existing premises and planned relocation to a new, purpose-built, world-class facility to support continued expansion and innovation.
Semiconductor research and development involves the use of a wide range of hazardous substances, including highly toxic, flammable, and pyrophoric gases, strong acids, solvents, and reactive chemical precursors. The inherent complexity and elevated risk profile associated with these materials required that process safety be embedded from the earliest stages of facility design, extending through detailed engineering, commissioning, and ongoing operation.
The Solution
Petro Safe supported the project from its early development stages, providing technical input during the preliminary assessment of the gas storage and supply building. This early-stage involvement focused on developing a compliant and robust design strategy, informed by industry best practice for gas separation and segregation. Particular attention was given to managing incompatibilities between gas species and ensuring appropriate separation from occupied areas, site boundaries, and ventilation intakes.
To further support the safety case, Petro Safe undertook consequence modelling using DNV PHAST to assess worst-case gas release scenarios, including catastrophic cylinder failure and the potential release of highly toxic materials through the ventilation system. The modelling results informed decision-making on the need for gas abatement systems, supporting a Best Available Techniques (BAT) assessment and enabling early progress toward Environmental Permitting. This evidence-based approach ensured that process safety considerations were fully integrated into both the design and regulatory strategy from the outset.