Part 2 of our five-part ‘Risk to Resilience’ blog series explores key practices in process safety management (PSM), how organizations can address key challenges, improve PSM performance, and build safer working environments.
High-risk industries depend on effective process safety management to protect the lives of workers, the efficiency of operations, and the environment. Below are five key PSM elements you need to get right and ensure your PSM processes are effective and meet compliance standards.
Management of Change
It’s said that the only constant is change, and it is especially true in industries like oil and gas, chemicals, and manufacturing. Even minor adjustments in equipment, procedures, and processes can pose major risks if not managed properly.
Every modification – such as the introduction of a new chemical, replacement or modification of equipment, an altered procedure, or assignment of new roles – needs to be evaluated, documented, and approved. This structured approach helps prevent incidents, ensures compliance, and keeps operations running smoothly.
Management of change (MoC) provides a structured way to ask: “What are the consequences of this change?” You need a robust MoC framework to anticipate risks before they occur and treat every change as an opportunity to reinforce safety and increase knowledge.
Process Hazard Analysis
Management of change helps control risks when conditions change, but there are inherent process hazards from the start that organizations also need to address. Process Hazard Analysis (PHA) provides a structured approach to systematically identify potential issues by asking: “What could go wrong?” and “What safeguards are in place?” Identifying hazards before they lead to incidents is essential for maintaining safety and operational integrity.
PHA methodologies like hazard and operability analysis (HAZOP) and What-If analysis make it possible for teams to see potential outcomes and create safer systems. Modern PHA tools apply advanced technologies and visual aids like bowtie diagrams to improve communication and simplify risk management.
By clearly visualizing and understanding risks, everyone stays safe. PHA is a pillar for protecting workers and ensuring operational excellence.
Asset Integrity
The first two elements discussed managing risks from changes and inherent hazards, and another critical piece to PSM is equipment reliability. In short, asset integrity and reliability focus on equipment failures that can lead to downtime, or worse, disasters with injuries or fatalities.
Regular inspections, maintenance, and real-time monitoring keep critical systems safe and dependable. Modern tools, like predictive analytics, help spot problems before they happen. This proactive approach minimizes risks, lowers costs, and ensures compliance. By prioritizing asset integrity, you’re safeguarding lives and creating sustainable success.
Safe Operating Procedures
Safety begins with clear instructions. Safe operating procedures and work practices guide teams through every step, from identifying hazards to planning tasks.
Proper training ensures everyone understands the processes and risks they face. When emergencies happen, preparedness becomes a lifeline. Clear communication and regular drills make all the difference.
Safety is a shared responsibility where every action must be deliberate, and every decision must consider safety.
Incident Management
The final core element of PSM is incident management because it ensures organizations learn from past events and prevent recurrences. Many catastrophic events are preceded by “warning incidents” or near misses. If these are ignored, the same underlying cause may escalate into a disaster.
Every incident or near miss is a golden opportunity to learn. By examining what happened and why it happened, organizations can determine the root cause and implement continuous improvement plans to prevent recurrence of incidents.
Every PSM foundation discussed – Management of Change, Process Hazard Analysis, Asset Integrity and Reliability, Safe Operating Procedures, and Incident Management – works together to create a culture of safety and operational excellence.
By prioritizing these five key pillars, your organization is taking the right steps to meet and exceed regulatory standards while also protecting lives, supporting business continuity, and creating a more sustainable future.
The actions you take today define the safety of tomorrow. If you’re ready to lead with purpose, please reach out to us.
Stay tuned for the next post in our Risk to Resilience blog series where we will explore the 5 Benefits of Digitizing Process Safety Management.
Wolters Kluwer Enablon Process Safety Management software and safety management tools let you implement a digitized PSM framework that identifies, evaluates and controls hazards related to processes using hazardous chemicals.
