(32ca) Training the Next Shift - Preserving Safety in the Face of Experience Loss

A critical element of an effective hazard analysis is the integration of knowledge from skilled operators familiar with the process under review. However, the chemical and refining industries face significant challenges in maintaining this expertise due to two emerging trends: an aging workforce and operational personnel constraints.

As experienced operators approach retirement over the next decade, there is a noticeable decline in the influx of young operators, leading to a concerning loss of practical experience. Additionally, many facilities operate with lean or "skeleton crews," resulting in fewer operators available for participation in hazard analyses (PHA). This situation typically leads to two problematic outcomes: either the most experienced operator is the only operator used, becoming overburdened with PHA responsibilities and hindering the training of other operators, or the least experienced operator is utilized, compromising the quality of hazard analyses due to insufficient practical knowledge.

These outcomes pose serious risks. Limited engagement in the hazard analysis process means the majority of operators remain unaware of critical risks within the facility. The involvement of inexperienced operators can result in unrecognized hazards due to their lack of practical experience. Moreover, a lack of emphasis from management on the importance of hazard analyses can foster complacency regarding process safety among operators.

To address these issues, consider the use of multiple operators in hazard analyses. This approach involves mixing experienced and inexperienced operators to facilitate knowledge transfer in a controlled setting. By rotating the operators involved in hazard analyses, this may ensure that most, if not all, operators engage in the process over their careers, thereby maintaining a high level of practical knowledge and vigilance. Although this strategy increases the cost of hazard analyses, it cultivates a workforce that is more engaged in process safety, ultimately reducing the risk of costly incidents.