Gleanings from the Industry
On the eve of a public holiday, a blending plant was operating swiftly to fulfil urgent customer orders. Amid the festive atmosphere, a maintenance supervisor suffered a serious injury while fixing an automated solenoid valve. His fingertip was severed. Quick action ensured the finger was preserved on ice, and he was taken to hospital, where it was successfully reattached.
This column is not a comprehensive retelling or investigation of that incident. Rather, it reflects on how it underscores the importance of vigilance, compliance and health, safety, security and environmental (HSSE) performance in plant operations. It is better to learn from such events proactively than through personal experience.
Chronic unease is a management mindset and a foundational principle in HSSE practices that seeks to eliminate complacency. HSSE begins at home and is continuously integrated into daily life. Below is my 10-point charter for achieving effective safety.
Safety Begins at the Top
Strong leadership and genuine commitment to HSSE are essential for safe operations. Prioritizing people’s wellbeing is key to achieving excellent HSSE outcomes. Everyone should have safe access to all operational areas, including welfare support and respectful interactions. While the use of appropriate personal protective equipment is important, it should never be relied upon as the primary safety measure.
Risk Assessment
The main operational approach involves designing plant facilities and systems according to the assessed level of risk. Achieving the lowest possible residual risk is the goal of optimal plant design. Automated blending and filling systems equipped with numerous fail-safe interlocks and controls are strong examples of this principle in action. “As Low As Reasonably Practicable” serves as the guiding principle for risk assessment and management.
Engineering Safety and Human Factors Engineering
In previous decades, blending plants primarily operated manually. However, this has largely changed with the adoption of automation. Despite these advances, the handling of drummed additives and packaging processes remains semi-manual in many facilities. It is essential to apply human factors engineering principles to ensure that all manual tasks are evaluated for ergonomic safety — for example, positioning manual valves at optimal heights, regardless of how infrequently they are used, and designing safe walkways free from interference by moving equipment.
License to Operate
Leaders earn a license to operate by ensuring the safety of lubricating oil blending plants. For new plants or design changes, cross-functional teams conduct key safety assessments:
EIA, HAZID, QRA: Environmental Impact Assessments, Hazard Identification Reviews and Quantitative Risk Assessments evaluate sustainability and identify risks to people, the environment, assets and reputation.
HAZOP: These studies assess process safety during design, examining flow, pressure, temperature, and safeguards.
3D Model Reviews: Teams verify that plant designs meet safety and operational requirements. Constructability reviews ensure that designs can be implemented safely and practically in the field.
PSSR and Other Reviews: Pre-Start-Up Safety Reviews, Operations Readiness, Emergency Response Preparedness, Management of Change and SIMOPs (for brownfield projects) provide independent checks before final approval.
Projects also undergo external validation, certification and licensing as required by local standards.
Simple, Unambiguous Procedures and Instructions
Operations and maintenance manuals form the foundation for safe system operation. Clear procedures define methods, roles and responsibilities for daily tasks and emergencies, minimizing subjective interpretation that can lead to safety incidents.
Permit to Work System
A permit to work is required for all non-routine activities at the plant, especially maintenance tasks. These activities carry safety risks and require thorough risk assessment and control measures before approval. High-risk jobs — such as confined space entry, work on energized systems and excavation near underground services — require stricter oversight under an enhanced permit system.
Reviewing the earlier incident shows that one contributing factor was improper work permit handling, as the technician attempted to manually test repaired equipment on a live pneumatic valve without proper safety precautions.
Stop Work Policy
All employees are empowered to report unsafe actions or conditions and may stop work if necessary to protect safety. This creates a trusted, shared system where everyone takes responsibility for maintaining plant safety.
Near Miss Reporting is Critical to Success
Any unexpected event — whether an actual accident or a near miss — should be reported promptly and systematically. Investigating, analyzing, and learning from these incidents is essential for maintaining safety and driving continuous improvement. The goal is to prevent recurrence and ensure ongoing safety through shared learning.
Visible Manifestation of Safety
A strong management system presents safety indicators clearly and transparently. Displaying relevant statistics and forecasting key performance supports proactive management. Posters, displays, and instructions help motivate staff, while regular campaigns, competitions, and ideation initiatives enhance engagement. Recognition through awards boosts morale and reinforces safe behavior.
Emergency Response Plans
Despite robust HSSE systems, unforeseen situations may arise. These require effective planning and regular drills to ensure preparedness. Emergency scenarios are developed based on plant-specific risk profiles, including fire incidents, hazardous spills and medical emergencies. Regular drills ensure readiness for both plant personnel and external agencies.
To sum up, as an operator, I strive to balance my professional responsibilities with family life. My day begins with family time, continues with a productive workday, and ends with a safe return home. Maintaining a safe workplace is my top priority and I believe every colleague shares this vision.
Happy Safety Day!
Ganesan Ganapathi has more than 40 years of experience as a supply chain and manufacturing professional with leading oil companies such as BP, Shell, Total and Bharat Petroleum. He also has noteworthy contributions in strategic and master planning, ranging from concept through commissioning and ramp up. He can be contacted via LinkedIn.