What do you do if your plant's safety measures need an upgrade with new technology?

Plant safety plays vital role in sustainability of product. All companies now focusing on zero incident in their organization, therefore, tools already adopted e.g. PSM, HIRA, Hazop, JSA, e- portal for reporting unsafe condition, unsafe behavior, incident reporting, 360 deg. implementation of new safety procedure . Due to growing need of safety, lot of work has been done in developing safety technology and advanced procedures are available. As initial step for improvement, thorough assessment of plant and process is required. Based on assessment gap analysis is done. These gaps need to be addressed using brain storming with in team or otherwise go for advance technology available for bring process to minimum risk.

RISK ASSESSMENT – CRITICAL EXAMINATION OF THE WORKPLACE TO CHECK THE POTENTIAL HAZARDS / CONTROL THEM - WHETHER THE RISKS ARE PROPERLY CONTROLLED IF NOT WHAT ADDITIONALLY CAN BE DONE TO CONTROL THEM is at a one time at one place, RISK ASSESSMENTS = IDENTIFY THE HAZARDS / CONTROLS RISK PROFILING - EXAMINE: they examine what are the type of risk is present, and as below point- 1 NATURE AND LEVEL OF THREATS IN THE WORKPLACE 2. LIKELIHOOD - POSSIBILITY OF RISKS BEING REALISED 3. LEVEL OF DISRUPTION OR LOSS FROM THE RISKS 4. AVAILABILITY AND EFFECTIVENESS OF CONTROLS

We're doing exactly this at our Baxenden site at the moment. We launched a project to install a HIMA safety instrumented system and a Siemens distributed control system to reactors that previously were all manually controlled. We conducted Human Factors assessments and carried out detailed HAZOPs to determine what SIL class of safety measures were required. We've completed four reactors so far and are about do upgrade our fifth one. There have been lots of challenges with logic and truth tables in the automation and some digital gymnastics to make it work, but we are getting better at it. Operators have the opportunity to see the "Old World" and the "New World" at the same time at the moment and the majority prefer the "New World".

1. Assess current safety measures. 2. Research suitable safety technologies. 3. Consult with experts and stakeholders. 4. Pilot test selected technologies. 5. Implement successful technologies. 6. Monitor and evaluate performance. 7. Continuously improve safety measures.

A thorough assessment is crucial for any work location safety improvement. Here are some additional thoughts to consider during this first step: Specific areas of focus: Beyond general safety protocols, we need to target areas with a history of incidents or near misses. Data analysis: Include accident reports, worker feedback surveys, and safety audits in the assessment. Compliance review: Ensure all current safety measures meet relevant industry regulations and standards. Additionally, involving a diverse group of stakeholders, you'll gain a well-rounded perspective on potential hazards and areas for improvement using new technology. This will ultimately lead to a more effective safety upgrade strategy.

In my experience, upgrading plant safety measures with new technology requires a holistic approach. Alongside assessing needs and researching tech, planning integration meticulously is essential. Training staff thoroughly ensures effective utilization, while testing systems rigorously before full implementation is crucial for identifying any potential issues. Regular reviews then guarantee continuous improvement and adaptation to evolving safety needs. This process ensures that our plant remains at the forefront of safety standards, safeguarding both our workforce and operations.

ASESS THE NEEDS The upgrade of the plant may arise from needs or requirements that govern the plant operation or safety. These could be regulatory in nature such as the requirement to conduct a review of the plant safety systems and programs every 10 or 15 years, as a condition of renewing the operating license. They could also be due to the plant equipment reaching their end-of-life; in this case the upgrade may involve refurbishing the plant equipment. A decision to upgrade the plant will face the challenge of refurbishing or replacing the existing equipment with new products and equipment that are developed under new standards and using new technology.

Perform scheduled gap analysis on safety systems; old or new. You may find recent technologies that can be used to mitigate hazards using engineering controls. On new systems you may need to do an initial analysis and then a final after the process has been in service.

To upgrade plant safety measures with new technology, follow these systematic steps: 1. Assess current safety measures, identifying weaknesses. 2. Research and evaluate new technologies based on effectiveness and cost. 3. Prioritize upgrades through risk assessment. 4. Engage stakeholders for input and decision-making. 5. Develop a detailed implementation plan with clear goals. 6. Provide training to ensure proper integration of new technologies. 7. Conduct pilot tests and gather feedback for improvements. 8. Deploy new technologies seamlessly into existing systems. 9. Monitor and continuously improve safety measures based on feedback and data. 10. Maintain detailed documentation for future reference and compliance.

A systematic approach to be used, risk assessment to be revised as per new technologies involvement. The changes in the process or technology to be communicated with employees and to be consulted for their feedback. A specific training to be arranged for the employees and a trail base opertion to be carried out prior to start the actual operation of the plant.

Research Tech As an example, in the nuclear industry, the first generation of nuclear power plants used hard wired analogue systems to control the Shutdown Systems, which constitute one of the defence lines against accidents causing the release of radioactivity from the plant. The upgrade of the control systems would seek the replacement of the hard-wired systems with the evolving digital systems at that time (mid 1980’s). Digital systems would offer great advantages, among them the online testing and the fact that the controlling software does not age or deteriorate. Despite the advantages offered by the new technology, there were risks in incorporating the new technology in systems design, which I will discuss under “ Risk Assessment”.

Here's how to refine the research on the latest safety technologies such as, targeting specific technologies based on our identified needs, research technologies like: -Predictive maintenance: Sensors that monitor equipment for signs of wear and tear, preventing unexpected failures. -Wearable technology: Real-time tracking of worker location, exposure to hazards, and providing alerts for potential risks. We need to look for technologies that integrate seamlessly with the existing systems for cost-effectiveness and a smoother implementation process. Also, we need to test promising technologies in a controlled environment before full-scale deployment.

Contact colleagues in different fields than your business. There are mew technologies that can be adapted to fit your needs.

Integration is an important aspect when two key measures integrate. Suitability and compatibility of the two have to be considered. Both must not have any clashes. I would also propose a test site before the implementation. Lastly a risk review should come in before the commencement and after the integration.

From my work experience with petrochemicals If your plant's safety measures need an upgrade with new technology, you should assess the specific safety gaps and explore how emerging technologies can address them. Conduct research, consult with safety experts, and evaluate different technological solutions before implementing any changes. Additionally, ensure that any new technology is compatible with existing systems and meets regulatory requirements. Regular training and communication with employees about the updated safety measures are also crucial for successful implementation.

Training plays a vital role, and here are additional ways to make it more effective such as: 1-Develop training programs specific to different employee roles and their interaction with the new technology. 2-Interactive learning and scenario-based training to make learning engaging and relevant to real-world situations. 3-Provide clear and concise user manuals and encourage easy access to reference materials for future reference. 4-Establish a system for ongoing support, including a help desk, Q&A sessions, and refresher courses to address questions and ensure continued proficiency. Consider offering incentives or recognition programs to encourage active participation and promote a culture of safety awareness.

Based on the published workplace incident statistics globally, it is well documented that 80-90% of workplace incidents / accidents are largely due to human errors. As such, training and competency for all employees should be a focal point especially with the introduction of new tech. These trainings should include both theory and practical so that employees can have 'hands-on' experience. In addition, as per any ISO management system, proper documentation of the procedures / working instruction to allow ease of reference. The implemented training system should also cater for refresher training and also on site supervision to monitor the newly joined employees to minimize errors that could led to potential incidents.

‏Additionally, hands-on training sessions and simulations can be valuable tools for reinforcing learning and allowing staff to practice using the new technology in a controlled environment. These sessions provide an opportunity for staff to ask questions, address concerns, and gain confidence in their ability to apply the safety measures effectively. ‏Furthermore, ongoing training and communication are crucial to ensure that staff remain up-to-date on safety protocols as technology evolves and new risks emerge. This can include regular refresher courses, safety meetings, and channels for reporting safety concerns or incidents related to the new technology.

Training plant staff on safety measures when upgrading to new technology involves several key steps. Firstly, it's essential to provide comprehensive education on the new technology itself, including its functions, features, and how it impacts safety protocols. This ensures that staff understand the purpose and operation of the technology, reducing the risk of errors or misuse. Secondly, staff should receive training on any updated safety procedures or protocols associated with the new technology. This may include instruction on how to safely operate the equipment, how to respond to emergencies specific to the technology, and how to mitigate potential hazards effectively.

Utilize ferramentas como Forms para identificar gap, obter feedbacks e assim promover ações de prevenção e melhoria. Ferramentas métricas são excelentes para comprar o passado com o prezente, facilitando um plano de ação acertivo.

With any new implementation at the workplace, a Management of Change (MOC) is critical to be established to ensure all key safety aspects are considered. Regular reviews are an essential mechanism to ensure that the performance are met so that effective changes can be implemented as part of continual improvement. These review should not just limited to certain specific groups of personnel but also includes the workers / operations feedback. Hence, an established feedback mechanism is important to gather information too. The reviews may include periodic inspections / audits which is part of the workplan so that it can be tracked.

Risk Assessment This step in upgrading the plant involves revisiting the “ safety case” of the plant and identifying the implications of introducing the upgrades on the performance and effectiveness of the plant safety systems. The safety case of the plant normally includes assessment all postulated hazards that could result from anticipated failures of the plant systems and means of mitigating the hazards. In the case of the nuclear power plants, this assessment is documented in a licensing document called “Safety Report”.

A real life example from a former employer: After identifying that our gas detection systems were outdated, we integrated advanced sensors capable of real-time monitoring and remote data transmission. This upgrade allowed for quicker response times and better hazardous gas management. The implementation involved detailed planning and staff training to adapt to the new system. Continuous evaluation has helped us fine-tune the technology, significantly enhancing our plant's overall safety.