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How can you ensure worker and public safety in process innovation projects?

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Process innovation is essential for chemical engineering, as it can improve efficiency, quality, sustainability, and profitability of products and services. However, it also involves risks and uncertainties that can affect worker and public safety, such as hazardous materials, equipment failures, human errors, and environmental impacts. How can you ensure worker and public safety in process innovation projects? Here are some tips and best practices to follow.

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Allyssa Brown

Senior Safety Engineer at Worley

1 Identify hazards and risks

The first step in ensuring safety is to identify the potential hazards and risks associated with the process innovation project. Hazards are sources of harm or damage, such as chemicals, electricity, pressure, heat, or noise. Risks are the likelihood and severity of harm or damage occurring from the hazards. You can use tools such as hazard and operability studies (HAZOP), failure modes and effects analysis (FMEA), and risk matrices to systematically analyze the hazards and risks of the process innovation project.

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Allyssa Brown

Senior Safety Engineer at Worley
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The step prior to analyzing risk via a Process Hazard Analysis (PHA) is to identify the inherent hazards using the Hazard Identification (HAZID) methodology outlined in t CCPS Guidelines for Hazard Evaluation Procedures. This tool provides a means to evaluate the potential hazards that are inherent to a process based on the materials being handled. This level of evaluation can be completed in the early development stages of a project because the main purpose is to ensure there are not inherently safer design options being missed, the planed safety management systems are sufficient based on the hazard, and required additional safety studies are identified early (surge analysis, dispersion modeling, etc.).

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2 Implement controls and mitigation measures

The second step in ensuring safety is to implement controls and mitigation measures to reduce or eliminate the hazards and risks identified. Controls and mitigation measures can be classified into four categories: elimination, substitution, engineering, and administrative. Elimination means removing the hazard completely, such as using a non-hazardous material instead of a hazardous one. Substitution means replacing the hazard with a less hazardous alternative, such as using a lower concentration or a different form of a chemical. Engineering means designing or modifying the equipment, process, or environment to prevent or minimize exposure to the hazard, such as using guards, valves, sensors, alarms, or ventilation. Administrative means establishing policies, procedures, training, or supervision to ensure safe work practices, such as following standard operating procedures, wearing personal protective equipment, or conducting regular inspections.

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3 Monitor and evaluate performance

The third step in ensuring safety is to monitor and evaluate the performance of the process innovation project and the controls and mitigation measures implemented. Monitoring and evaluation can involve collecting and analyzing data, such as process parameters, quality indicators, safety indicators, and feedback from workers and customers. Monitoring and evaluation can help you identify any deviations, problems, or opportunities for improvement in the process innovation project and the safety measures. You can use tools such as statistical process control (SPC), key performance indicators (KPIs), and audits to monitor and evaluate the performance of the process innovation project and the safety measures.

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4 Communicate and collaborate

The fourth step in ensuring safety is to communicate and collaborate with all the stakeholders involved in the process innovation project, such as workers, managers, customers, suppliers, regulators, and the public. Communication and collaboration can help you share information, ideas, feedback, and concerns about the process innovation project and the safety measures. Communication and collaboration can also help you build trust, engagement, and commitment among the stakeholders. You can use tools such as meetings, reports, presentations, newsletters, or social media to communicate and collaborate with the stakeholders.

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5 Learn and improve

The fifth step in ensuring safety is to learn and improve from the process innovation project and the safety measures. Learning and improving can help you identify the strengths, weaknesses, opportunities, and threats of the process innovation project and the safety measures. Learning and improving can also help you implement changes, corrections, or enhancements to the process innovation project and the safety measures. You can use tools such as lessons learned, root cause analysis, or continuous improvement to learn and improve from the process innovation project and the safety measures.

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6 Foster a culture of safety

The sixth and final step in ensuring safety is to foster a culture of safety in your organization and your process innovation project. A culture of safety is a set of values, beliefs, attitudes, and behaviors that support safety as a priority and a responsibility for everyone. A culture of safety can help you create a positive and proactive environment where safety is integrated into every aspect of the process innovation project and where workers and managers are empowered and accountable for safety. You can foster a culture of safety by setting clear and realistic goals, providing adequate resources and incentives, encouraging participation and feedback, recognizing and rewarding achievements, and promoting learning and improvement.

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Allyssa Brown

Senior Safety Engineer at Worley
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A main component to fostering a culture of safety is Management of Change (MOC). The purpose of MOC is to manage the risk profile of the process developed during the Process Hazard Analysis (PHA) stage of the process innovation project. It is important to remember MOC does not start after the completion of system design or the construction of process, but rather when the final PHA evaluation on the system is completed, setting the risk profile for the project. You want to ensure your MOC process provides a means to record, track, and evaluate the impact of change. and identify and record changes that adversely impact the risk profile. Any changes that impact the risk profile need to be evaluated by the PHA or intellectually equivalent team.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you ensure worker and public safety in process innovation projects?

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1 Identify hazards and risks

2 Implement controls and mitigation measures

3 Monitor and evaluate performance

4 Communicate and collaborate

5 Learn and improve

6 Foster a culture of safety

7 Here’s what else to consider

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