The Vital Role of Hazard Identification
Industrial processing facilities like gas plants, refineries, or chemical plants operate with a complex network of processes and systems, where the slightest oversight can lead to catastrophic consequences. Amidst this backdrop, the significance of hazard identification cannot be overstated. It serves as the linchpin in ensuring the safety and reliability of these critical operations.
When hazards are not identified and go unmitigated the result is often serious incidents. One of the worst industrial accidents in the history of the process industry was the Union Carbide incident in Bhopal, India, 1984 which killed thousands and resulted in countless injuries and illnesses (Learn more HERE). A core cause of that event was a lack of understanding of the reactive hazards of the process in the plant.
More recently, in the 2019 explosion at KMCO’s chemical plant one worker was killed and there were multiple injuries. The US Chemical Safety Board (CSB) highlighted a lack of hazard identification and a poorly documented Process Hazards Analysis (PHA) in their report (Link HERE). A 2014 PHA failed to identify thermal expansion hazards and a subsequent PHA in 2015 only analyzed two of sixteen nodes leaving the hazards unknown and unmitigated.
Sadly, the lesson to perform rigorous hazard identification studies and implement findings is a lesson the industry is still learning over and over today.
Understanding Hazard Identification
Hazard identification involves the systematic examination of potential hazards and threats that could jeopardize the safety, integrity, or efficiency of industrial processes. Process Safety frameworks from CCPS, to OSHA or CSA list understanding risks as one of most important pillars in the structure of their programs. Without identifying hazards it is impossible to ensure they are mitigated and the risk of unsafe days increases dramatically.
There are many common tools including HAZOP, HAZID, What-if? Analysis and more. These Process Hazards Analysis (PHA) methods ensure a comprehensive analysis of various factors, including equipment failures, human errors, and external conditions. The risks are associated with the operating company’s impact receptors including health and safety, regulatory, environmental, reputation or financial.
Mitigating Potential Hazards
Identifying hazards to operations is just the first step; the real value lies in mitigating these risks effectively by applying the hierarchy of controls. By proactively recognizing potential hazards, industrial facilities can implement targeted measures to minimize or eliminate risks altogether. This could involve upgrading equipment, implementing stricter safety protocols, or redesigning processes to enhance resilience against potential threats.
Integration with Training
Risk awareness serves as the foundation for robust training and programs within industrial facilities. Through comprehensive risk assessments, organizations can tailor training modules to address specific hazards and equip employees with the knowledge and skills needed to navigate potential risks safely. This can be detailed in a competency requirement matrix aligning the required training with the appropriate roles.
Integration in Maintenance
Similarly, risk-based maintenance strategies ensure that equipment is inspected, serviced, and upgraded in accordance with the level of risk posed, thus reducing the likelihood of unexpected failures or accidents. The risk assessments can serve as a mechanism to identify safety critical elements that require special attention and care in their maintenance.
Driving Prevention Efforts
Prevention is always preferable to remediation in the realm of industrial safety. Hazard identification empowers organizations to proactively identify potential vulnerabilities and implement preventive measures to mitigate them. Whether it involves installing redundant systems, enhancing monitoring capabilities, or implementing stringent safety protocols, a proactive approach to risk management significantly reduces the likelihood of incidents occurring.
Informing Emergency Planning
Despite best efforts in risk mitigation, emergencies can still arise. However, through rigorous risk identification, industrial facilities can develop robust emergency response plans tailored to address specific scenarios. By anticipating potential risks and their corresponding consequences, organizations can streamline emergency protocols, allocate resources effectively, and minimize the impact of incidents on personnel, the environment, and surrounding communities.
Putting it in Action
By systematically identifying, assessing, and mitigating potential hazards, organizations can safeguard their operations, protect personnel, and uphold their commitment to environmental stewardship and community well-being. Moreover, risk awareness transcends individual processes, informing critical aspects of training, maintenance, prevention, and emergency planning.
As industrial facilities continue to evolve and face new challenges, the importance of robust risk identification practices remains unwavering—a beacon guiding the way towards safer, more resilient operations.
Did you know that the PSM Experts at Rskless have more than 100 years of combined experience to share from supporting clients in hazard identification and PSM in general?
Don’t be reckless! Contact RskLess today for the best advice and support in executing comprehensive risk assessments to identify hidden hazards in your operations.
