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

DSEAR is one of the more demanding pieces of UK safety legislation to comply with, because it does not sit in a single d...
07/09/2026

DSEAR is one of the more demanding pieces of UK safety legislation to comply with, because it does not sit in a single discipline. It asks process, mechanical and electrical questions at once, and it applies to far more sites than realise it. If you store, handle, process or produce anything that can burn, explode or release energy in an uncontrolled way, it applies to you. Combustible dusts from milling, blending, drying and conveying are caught by the same Regulations, as are substances that only become dangerous under particular process conditions.

The Regulations and Approved Code of Practice L138 require you to identify your dangerous substances and assess the risk, eliminate what you can and control the rest in the Regulation 6 priority order, classify where explosive atmospheres can form and make the equipment in those places suitable, plan for the emergency, and make sure your people understand what they are handling. Each of those carries technical judgement that is difficult to make from the inside: whether a zone extent is defensible, whether ventilation genuinely supports the classification, whether an Ex equipment category is correct for the installed conditions. Getting it wrong is not obvious until an inspector, an insurer or an incident makes it obvious.

DSEAR is core work for Projex Solutions. We deliver it across chemical, pharmaceutical, FMCG and energy sites, and we have structured it into defined deliverables that each close a specific part of the duty. That structure is set out in our DSEAR Toolkit, developed in-house so that clients can see exactly what the Regulations require and how each requirement gets closed out.

Understanding DSEAR can be complicated, but you do not have to work this out alone. Let us help apply the judgement that comes from doing this type of work regularly, and give you a clear, prioritised view of where you stand and what it will take to close the gap.

If DSEAR applies to your site and you want experienced engineers to assess your requirements properly, talk to Projex Solutions.

Look closely at incident and failure investigations in process manufacturing and a pattern emerges. The cause is rarely ...
06/09/2026

Look closely at incident and failure investigations in process manufacturing and a pattern emerges. The cause is rarely contained within one discipline. It sits at the join between them, in the space where each specialist reasonably assumed someone else had it covered.

The examples are familiar. A pump is correctly sized by process and mechanically sound, but the motor starter and cabling were specified before the duty changed. An interlock is designed to the right SIL, then defeated in practice because the operating procedure made it unworkable. A vessel modification is mechanically fine and quietly invalidates the relief case. A control narrative and the P&ID disagree, and the plant runs to whichever the operator trusts. None of these are failures of individual competence. They are failures of interface, and single-discipline reviews are structurally poor at catching them.

Projex Solutions is built as a multi-discipline practice for that reason. Process, mechanical, EC&I, process safety and project management sit in the same team on the same project, with defined interface responsibilities and design reviews that deliberately test the joins. HAZOP, HAZID and design review sessions are run with all relevant disciplines in the room, so the assumption one discipline makes about another gets challenged while it is still a drawing.

If you are dealing with a recurring problem that no single discipline has managed to close out, talk to Projex Solutions.

ATEX compliance rests on a chain of decisions: where can an explosive atmosphere form, how often and for how long, what ...
05/09/2026

ATEX compliance rests on a chain of decisions: where can an explosive atmosphere form, how often and for how long, what zone does that make it, and is every piece of equipment in that zone certified and installed for it. The chain only works from a correct starting point. If the zone is wrong, the equipment selection built on it is wrong too, however impressive the certification paperwork looks.

Zones drift. A dust hazard is introduced when a new powder handling step is added and the classification is never revisited. Ventilation assumed in the original assessment has since been altered. Equipment is replaced like for like on the maintenance system without an Ex specialist checking the category and temperature class. Cable glands and enclosures are opened during a repair and closed without restoring the type of protection. Inspection under EN 60079-17 lapses, so no one is looking. On a UK site, the same facts also sit under DSEAR, and an inspector will ask to see both the classification and the evidence behind it.

Projex Solutions works from the classification upwards. We carry out DSEAR assessments and hazardous area classification with issued zone drawings, specify and verify Ex equipment selection, provide CompEx-competent inspection and design, and deliver the EC&I engineering needed to bring installations into line. Where we find a gap, we set out a prioritised, practical route to closing it.

If you are unsure whether your zone drawings still describe your plant, talk to Projex Solutions.

We enjoyed another Bring Your Own Buffet at the Brighouse office last week... though not the one we had planned.The inte...
04/09/2026

We enjoyed another Bring Your Own Buffet at the Brighouse office last week... though not the one we had planned.

The intention was to have a barbecue on the Friday before the Bank Holiday weekend. What we got instead was a yellow weather warning for thunderstorms and an Environment Agency flood alert. We assess risk for a living, so in the most British way possible we moved indoors and enjoyed sandwiches instead.

The format for a Bring Your Own Buffet is simple: colleagues bring a dish that means something special to them, and the table ends up as varied as the team is. We ran the first one last year and it has stuck, because it does something a scheduled meeting cannot. People end up talking to colleagues they rarely get time with.

Brian Lawson, our Technical & Quality Director, delivered a business update over lunch, covering where we are and what is coming next, and after that it was food, conversation and an hour to actually relax before the long weekend. It sounds like a small thing, but a team that enjoys sitting down together is a team that works better when the pressure is on.

Thank you to everyone who attended.

We're thrilled to be celebrating 14 years at our Brighouse offices!St Pegs House has been home to Projex Solutions since...
03/09/2026

We're thrilled to be celebrating 14 years at our Brighouse offices!

St Pegs House has been home to Projex Solutions since 2012. In that time it has been the starting point for hazard studies, design reviews, site visits up and down the country, and a great many projects that began as a quick sketch on someone's desk and ended up fully built on someone else's plant.

Buildings do not make a business, people do. But a good one gives you somewhere to think properly, argue about a P&ID, welcome a client, and put the kettle on afterwards. This one has done all of that for fourteen years.

Thank you to the team who fill it, and to the clients who keep coming through the door.

Here's to the next one.

Our 2026 EcoVadis assessment results are in. Projex Solutions scored 64 out of 100, up from 61 in 2025. EcoVadis assesse...
02/09/2026

Our 2026 EcoVadis assessment results are in. Projex Solutions scored 64 out of 100, up from 61 in 2025. EcoVadis assesses sustainability performance across four themes - Environment, Labour and Human Rights, Ethics, and Sustainable Procurement - and it works on documented evidence rather than stated intent, so the score only moves when the underlying management system does.

This is the same standard we apply to client projects. Sustainability, like safety, is a management and engineering discipline that is measured on evidence, not ambition. Clients across chemical, pharmaceutical, FMCG and energy increasingly assess their supply chain on exactly these criteria, and an EPCM partner who cannot evidence its own environmental management becomes a gap in someone else's reporting.

If you are assessing your engineering supply chain, or want a partner who treats sustainability as a design and delivery parameter, talk to Projex Solutions.

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.

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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