- Consultancy
DSEAR Gap Analysis – Compliance Review and Hazardous Area Assessment
The “Blue Card”
What Is It?
A DSEAR Gap Analysis is a structured review designed to evaluate how well an organisation complies with the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR). This analysis identifies gaps in existing controls, documentation, zoning, and risk assessment practices, helping duty holders understand their current level of compliance and the actions required to meet UK legal obligations.
A DSEAR Gap Analysis differs from a full risk assessment in that it focuses specifically on:
- Identifying missing or outdated elements of existing DSEAR documentation
- Reviewing the suitability of hazardous area classification (HAC)
- Checking alignment withHSE ACOP L138, ATEX requirements, and the IEC 60079 series
- Assessing whether organisational processes and controls reflect current engineering and operational reality
This service provides a clear, evidence-based roadmap to achieve compliance and prepare for audits, inspections, or follow-up verification work.
Who It’s For?
This service supports organisations that store, handle, or process flammable gases, vapours, or combustible dusts, including:
- Refineries and petrochemical plants
- Power generation and BESS energy storage facilities
- Chemical and pharmaceutical sites
- Water and wastewater treatment works
- Food, beverage, and biomass-processing facilities
It is particularly valuable for:
- Duty holders responsible for maintaining DSEAR compliance
- Engineering, maintenance, and project teams
- Sites preparing for audits, inspections, or insurance reviews
Organisations with legacy DSEAR assessments requiring update or verification
Why It Matters
A DSEAR Gap Analysis helps organisations understand the status of their plant and assets highlighting areas which of non-conformance with suggested corrective actions to resolve. Without accurate and up‑to‑date information, sites are venerable to:
- Incorrect zoning or unsuitable equipment selection
- Over‑zoning leading to unnecessary expenditure or design restrictions
- Non‑compliance with DSEAR, IEC 60079‑10, IEC 60079‑14, and industry codes of practice
- Audit failures or enforcement action from regulators
- Increased risk of fires, explosions which could lead to safety, environmental and production losses.
HSE guidance (L138) emphasises that DSEAR assessments must be current, evidence‑based, and reviewed periodically, typically every 3–5 years or following significant changes.
Our Approach
Our engineers carry out a structured, defensible review aligned with HSE ACOP L138 and the relevant IEC 60079standards, along with industry codes of practice such as EI 15 and IGEM/SR/25. A typical DSEAR Gap Analysis includes:
- Documentation Review– Assessment of existing DSEAR reports, HAC drawings, P&IDs, MSDSs, maintenance records, and safety systems.
- Site Walkdown– Verification of real‑world conditions, ignition sources, operating practices, and protective measures.
- Gap Identification– Highlighting omissions, outdated data, incorrect zoning, or missing risk justifications.
- Standards Compliance Check– Comparison against legal and industry requirements.
- Action Prioritisation– Clear recommendations categorised by urgency and compliance impact.
- Integration with Future Work– Alignment with upcoming DSEAR risk assessments, HAC studies, or verification programmes.
This review provides organisations with a clear understanding of where they stand and what steps are needed to close compliance gaps.
Outcome
A complete and traceable summary of DSEAR compliance, including:
- Summary report highlighting compliance gaps and required actions
- Updated or verified hazardous area classification recommendations
- Clear prioritisation of control and mitigation measures
- Evidence package suitable for regulatory, audit, or insurance review
Water - Area Manager
“The E-learning is a great alternative to travelling to a classroom. We were able to sit the training while we waited for the weather to clear up. The team are very helpful, it was nice to be able to pick up the phone and speak to a real person – Thanks for your help Clio!”
Related Services
- Classroom
- Certified
- On-site
- Classroom
- Certified
- On-site
Benefits for Learners and Managers
- Foundation for safety culture: Establishes a common language and awareness of process safety across the workforce.
- Improved compliance: Supports regulatory requirements and industry standards set by the PSMCPB.
- Flexibility in delivery: Choose between direct delivery or train‑the‑trainer licensing to suit organisational needs.
- Reduced risk of incidents: Ensures staff understand their role in preventing accidents and responding effectively when things go wrong.
Course Content
- Introduction to process safety – definitions, key concepts and differentiation from occupational safety.
- Legislation and standards – overview of health and safety legislation relevant to high‑hazard industries.
- Hazard and risk identification – tools and techniques for recognising hazards and assessing risks.
- Mitigation measures and emergency response – understanding available mitigation measures and the role of emergency response.
- Consequences of process safety failures – case studies and workshop activities illustrating real-world impacts.
Key Information
Useful Information
- Service:DSEAR Gap Analysis
- Core Standards:HSE L138, IEC 60079‑10‑1 / -10‑2, IEC 60079‑14, EI 15, IGEM/SR/25
- Outputs:Compliance report, zoning review, prioritised action plan
- Linked Regulations:DSEAR / ATEX
- Review Frequency:Every 3–5 years or following plant change
Who We Work With
- COMAH and high‑hazard site operators
- Engineering and process safety teams
- Electrical, instrumentation, and control engineers
- Project and maintenance teams needing verification support
Common Triggers for Review
- Modifications to plant or process
- New or substituted substances
- Changes to ventilation or containment
- Audit findings or equipment upgrades
- Regulator or insurer requests
Deliverables
- Combined compliance gap report
- Reviewed or updated zone classifications
- Traceable justification for zoning decisions
- Recommendations for compliance improvement
FAQs
A structured evaluation of how well an organisation meets DSEAR requirements, focusing on documentation gaps, zoning accuracy, and control measures.
A Gap Analysis identifies missing or outdated elements but does not replace a full assessment. It helps determine what additional work is required.
HSE L138, IEC 60079‑10‑1 / -10‑2, IEC 60079‑14, EI 15, and IGEM/SR/25.
Every 3–5 years or following modifications to processes, substances, or ventilation.
Yes. Ecfio frequently reviews and updates older or inconsistent DSEAR documentation.
P&IDs, site plans, ventilation data, MSDSs, equipment lists, and access to operational personnel.
We provide a prioritised action plan and, if required, can support follow‑up DSEAR risk assessment, HAC studies, and verification work.
To review your current DSEAR compliance status or schedule a site visit:
📧 support@ecfio.co.uk
📞 +44 (0)19 3296 3463