In any industry where complex processes and hazardous materials are involved, maintaining a high standard of process safety is essential. Process safety focuses on prevention through mitigation of potential causes that lead to consequences for catastrophic events. Accidents like chemical spills, explosions, or toxic releases can be devastating, and identifying the warning signs (or "red flags") early can prevent these events from happening. Recognizing and identifying these red flags is essential in managing process safety. While every operation carries its own risks, addressing these warning signs can prevent hazards from turning into accidents or catastrophic failures. Promoting a safety culture that has open communication between team members, maintaining equipment, and staying up to date on operator training and knowledge are key factors in maintaining a safe working environment for all involved. So, what are some of the red flags you should keep an eye out for?

→Addressing a change after it has taken effect or an Ineffective Management of Change Procedure

A significant red flag I’ve frequently encountered is facilities utilizing their Management of Change (MOC) procedures after the change has already occurred. This is problematic because it undermines the core purpose of the MOC procedure, which is to assess and mitigate risks before the change is made. The MOC process is designed to ensure that safety, operational, and environmental hazards are properly identified and managed. When changes are implemented without prior review, it increases the risk of unforeseen consequences, equipment failures, or unsafe conditions. Post-change MOC reviews put both employee safety and equipment integrity at risk, potentially leading to accidents, non-compliance, or catastrophic failures. If your management of change procedures is only a checklist, then your MOC program is mostly likely is not very robust.

→Lack of Operator Training

Untrained operators are one of the most significant threats to process safety. All too often, operators are thrust into operation rolls with little to now training or given a false understanding that a “one week” course is sufficient for operating a process. Coupled with poor operating procedures, is a recipe for serious incidents and injuries. Training also must include methods for communication of operational concerns and deficient equipment.

→Outdated Safety Procedures

Safety protocols and procedures must evolve in response to changing technologies, equipment, and regulations. Outdated or non-standardized procedures can lead to confusion during operations, especially in critical situations.

→Failure / Ineffective Mechanical Integrity

Regular maintenance of equipment is required and helps to prevent mechanical failures that could lead to process accidents. Delaying or ignoring routine inspections and repairs is a red flag that could hint at deeper issues within the organization’s commitment to process safety. An effective and robust mechanical integrity program begins with detailed and effective mechanical integrity procedures. Relying on a checklist will ensure a box is checked perhaps, but says nothing about is the task is to be performed or better still, what is to be done when the results are not what is expected or not within the design specifications or process safety information.

→Lack of Communication

Poor communication between team members, shifts, or between operators and managers can result in safety information being missed or ignored. Miscommunication about process changes, hazards, or emergency response actions can lead to serious consequences.

→Outdated Process Safety Information

Process Safety Information (PSI) is the basis for everything. Starting with or not maintaining current accurate PSI has led to many process safety events including fatalities. The design information or PSI is how a facilities measure mechanical integrity inspections and results to ensure equipment is maintained to design specifications. Missing or inaccurate PSI is essentially taking a chance that all is going to be okay!