What DSEAR requires you to do
At its core, DSEAR requires you to:
- Assess risks from fire and explosion caused by dangerous substances
- Eliminate or reduce risk so far as reasonably practicable
- Control ignition sources and mitigate consequences
- Where explosive atmospheres may occur, classify hazardous areas (zones), select suitable equipment, mark zones, and ensure verification and protection arrangements
A thorough DSEAR assessment typically includes
1) Substance and process mapping
- What dangerous substances are on site (including by-products and dusts)
- Where they are stored, used, created, transferred, and disposed of
- SDS review and realistic operating conditions (not “work as imagined”)
2) Identification of hazardous scenarios
- Loss of containment, leaks, spills, venting, overfill
- Dust releases at transfer points, bag emptying, sweeping, maintenance
- Abnormal operations: start-up/shutdown, blockages, filter changes, breakdowns
Good DSEAR looks hard at “normal” and “foreseeable abnormal” operation.
3) Explosive atmosphere assessment and zoning (where needed)
If you can form an explosive atmosphere, DSEAR may require zoning for gases/vapours and for dusts. Zoning is based on likelihood and persistence.
4) Ignition source control
This includes, at minimum:
- Electrical and mechanical equipment suitability
- Static electricity risks (people, powders, packaging, conveyors)
- Hot work, non-routine work, maintenance tasks
- Vehicles and FLTs in risk areas
- Overheating bearings, friction, misalignment
HSE links zoned areas to protection from ignition sources and equipment selection.
5) Existing controls vs required controls (gap analysis)
Using the hierarchy of controls:
- Can we eliminate or substitute?
- Can we contain or reduce releases?
- Can we ventilate or segregate?
- Are controls maintained, verified, and owned?
6) Consequence mitigation
Depending on the scenario:
- Explosion relief/venting, suppression, isolation
- Fire detection, emergency response, separation distances
- Permit-to-work controls and “serious and imminent danger” arrangements
7) Clear, prioritised action plan
This is where most competitors fail. The best assessment gives:
- A short list of actions with owners, deadlines, and rationale
- Procurement and maintenance rules that prevent drift
- Practical “do this, not that” guidance for operations
Deliverables you should expect
- DSEAR risk assessment document (suitable and sufficient)
- Hazardous area classification drawings or zoning maps (if needed)
- Equipment suitability recommendations (linked to zones)
- Practical controls and operating rules
- A maintenance and inspection strategy that keeps it live
If you have a DSEAR already but it’s vague, overly long, or not linked to actions and equipment decisions, we can review it and tell you what’s missing in plain English.
