(100c) Quality Problems As Process Safety Warning Signs

Author: John Herber, Principal Consultant, Process Hazard Management Services, LLC.

Many companies collect and report process safety incidents. Some may collect process safety near misses. Many of these are initiated by a process parameter that exceeds its safe operating limit, a critical safety system is activated or a release of hazardous material occurs.

This paper will explore how a quality issue on a batch reactor could be a warning sign for several key prevention systems. As an example, a poorly controlled exotherm could be a warning sign for an imminent problem with the cooling equipment, the raw materials, procedures, or training. Many of the problems that cause quality problems are subtle such as fouling of cooling surfaces or a valve that occasionally sticks. If these issues continue unchecked, the conditions will occur, perhaps with a worse outcome.