Management of Change Compliance is the Key Indicator of Next-generation Process Safety Maturity: PK Goswami

With digital systems today providing real-time data through sensors and integrated control platforms, how can organisations ensure that this connected data leads to timely command-driven decisions during process deviations rather than remaining limited to monitoring dashboards.

Whenever there is a process, any kind of malfunctioning or deviation from the standardised process is detected. If there is any deviation, the sensor system automatically gives a command to the control system. It then takes the necessary actions as already designed and specified. This saves time and also prevents disasters.

Before something happens, it stops the process. For example, if a machine operator puts their hand near the point of operation where there may be a blade, once the sensor detects it is a danger zone, the photocell automatically cuts off the machine. It stops, saves life, prevents injury, and safeguards the workplace. That is a constructive perspective.

Traditional Hazard and Operability (HAZOP) and risk studies are periodic in nature. In higher hazard operations, how can risk assessment frameworks evolve to become more contextual and dynamic, particularly during change management, maintenance shutdowns and simultaneous operations?

HAZOP is a continuous process. Whenever there is any change in equipment, based on the Piping and Instrumentation Diagram (P&ID), there will be associated hazards. It is a very good method and cannot be outdated. Additional information can be obtained through monitoring systems, and inputs can be incorporated. For example, HAZOP recommendations specify certain actions to be taken. These actions can be supported through AI from various sections and incorporated from a compliance point of view. In that case, the compliance level will be higher.

As industrial facilities become increasingly digitalised, how should regulatory oversight adapt, and should inspection models move towards risk-based, data-driven and digitally integrated compliance mechanisms?

We are in the process of that. We are categorising factories based on hazard levels—high, medium and low. Where there is higher hazard, we are taking various operational and statutory requirements from them through returns and online databases. They have to upload the latest developments, including the type of new hazardous materials being introduced, and update the departments. Accordingly, a web-based inspection system and a randomised inspection system are being implemented. Inspection reports will also be automatically uploaded within 24 hours.

For installations located near urban clusters, how can process safety management integrate on-site emergency systems with district authorities and disaster management agencies to enable a unified command response?

In Delhi, in 2019, we developed an off-site emergency plan based on on-site emergency plans. There are about 16 major accident hazard installations in Delhi. We have integrated all these installations under the platform of the National Industrial Management Authority.

"“We have learned from past incidents that if surrounding areas are informed in time—for example, to cover the mouth with a wet cloth and move away from the wind direction—many lives can be saved”"

The District Magistrate is the chairman of this committee, and as part of the factory inspectorate, I am the member secretary. Various departments such as municipal authorities, pollution control, fire services, police and hospitals are stakeholders in this system. When there is an on-site emergency within the premises, it is handled internally. Once it goes beyond the boundary of the installation, it is taken over by the district crisis group. We take over the entire response system, activate all stakeholders and nearby people, and implement immediate emergency, evacuation and rescue plans, which are then tracked.

Besides, neighbourhood training is important. Initially, industries were set up outside cities, but now populations have settled nearby. To address this, as per legislative provisions, we involve local leaders, village representatives and doctors to make them aware of the hazards associated with the industry. In case of any disaster, such as a toxic chemical leak, fire or explosion, they can be activated immediately.

We have learned from past incidents that if surrounding areas are informed in time—for example, to cover the mouth with a wet cloth and move away from the wind direction—many lives can be saved. Following amendments in the law, this system is now in place, and awareness programmes for surrounding populations are being conducted.

Beyond incident statistics, which technical leading indicators should define next-generation PCM maturity?

Management of change compliance is the most important point, as it connects to behaviour. The other aspects discussed initially are equipment-based, but unless they are adopted with ownership of safety and health, they cannot be implemented. Therefore, the level of compliance becomes the key indicator and a measure of maturity in this context.