Page 96 - Serious Incident Prevention How to Achieve and Sustain Accident-Free Operations in Your Plant or Company

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74 Serious Incident Prevention

Quality control deficiencies leading to installation of a pump incom-
patible with process requirements.

A Systematic Process of Risk Identification

Identifying and understanding significant risks for a major operation or
facility requires a comprehensive, systematic approach. An effective
process for a petrochemical facility, for example, will generally require at
least the following:

Input from operating, staff, and management personnel with opera-
tional expertise
Process hazard analyses
A system for employees to report suspected deficiencies related to
any aspect of the incident prevention process
Management-of-change reviews
Near-miss and accident investigations
Field inspections
Management briefings regarding specific serious-incident-related
risks
Networking through trade associations and safety groups
Review of investigative reports for incidents experienced by other
companies
Evaluation and compliance with regulatory standards such as the
OSHA Process Safety Management standard
Evaluation of applicable statistical summaries and technical infor-
mation regarding the causes of accidents
Computer modeling or other evaluation of the range of consequences
for potential incident scenarios

Maintaining an adequate understanding of risks inherent in complex
operations is truly a neverending journey. The process requires perception,
attention to detail, dedication, and a keen thirst for knowledge. The disci-
pline and courage to challenge assumptions is critical. Experience confirms
that rather than “what you don’t know,” the real danger is often linked to
“what you think you know that isn’t so.” In traveling, the occasions where
we become lost tend to be those where we are certain of the proper route—
so certain that we fail to confirm the address or obtain directions. In oper-