Operating facilities, in order to increase capacities, try to carry out modifications in the equipment, replace some, change process parameters, etc. This can also be done through bypassing of safety systems, to achieve quick gains. While doing all these, if the consequences on safety of the personnel, environment and property are not analyzed, then it is likely that some foolish action will lead to total closure of the plant one day. Any change proposal should undergo HAZOP/WHAT IF/ETA/FTA studies. The design should be carried out only by experienced persons and safety studies should be carried out by safety professionals. If it is done by some entry level person and is endorsed by higher ups without review, we may be inviting the disaster.
Even though the safety studies will be time consuming, it is worth doing before carrying out changes rather than repenting later. Top management should recognize this and support the safety programmes. Else, shortsightedness will shut the plant at a later date. Though, it is easy to blame safety department at that time for not doing their job, one should introspect whether the advise of safety officer was given due importance or not.
Management of change is an important activity and shall be followed by all facilities, irrespective of their size, nature of work and product.
