Process Safety Intelligence: The Plant That Remembers pdf

Every HAZOP creates knowledge. Almost no organization is built to keep it.

Walk into any revalidation and the questions begin: Why was this recommendation made? What were we trying to prevent? Why was this safeguard considered enough? The report holds the decision. The reasoning left with the people who made it.

For fifty years the process industries have invested heavily in finding hazards — HAZOP, LOPA, SIL, management of change, incident investigations. Each produces something more valuable than a report: understanding. And most of it is lost as facilities change and experienced engineers retire.

Process Safety Intelligence argues that the next major advance in process safety won't come from a better analysis method or smarter software. It will come from treating engineering knowledge itself as a long-lived operational asset — preserved, connected, and continuously applied across the life of a facility.

Drawing on hard lessons from Longford, Piper Alpha, Texas City, and other landmark investigations — and looking ahead to open architectures and artificial intelligence — Trevor Cusworth introduces a new discipline and a practical path to building it.

Inside, you'll find:

• Why organizations forget, and the seven mechanisms behind it
• The "Knowledge Layer" that connects records, reasoning, and relationships
• How continuous revalidation replaces reconstruction with evaluation
• A maturity model and self-assessment to locate your organization today
• A step-by-step program, a business case, and honest answers to the toughest objections

Written for process-safety engineers and managers, operations and maintenance leaders, and the automation professionals modernizing the systems these plants run on.