Modernizing Process Safety Management: From Static Assessments to Dynamic Risk Control

Process Safety Management (PSM) plays a central role in protecting people, assets, and the environment. However, many organizations still rely on static, document-based approaches to manage risk. Process Hazard Analyses (PHAs), such as HAZOP or FMEA studies, are typically conducted every few years or after a major incident. The results are often stored in paper reports or static digital files, which quickly become outdated as operations evolve.

In reality, risk is not static. Over time, changes in personnel, equipment, procedures, plant layout, or materials can introduce new hazards or increase exposure to existing ones. At the same time, the effectiveness of barriers and controls can degrade if not actively monitored and maintained. Without a system that reflects these changes in real time, frontline workers may be operating with incomplete or outdated information.

Digital transformation offers a practical solution to this challenge. By integrating PSM activities into a connected digital platform, organizations can ensure that safety-critical information is continuously updated, validated, and accessible. A digital control of work (CoW) system, for example, can interface with maintenance management systems, real-time plant data, and other operational platforms through APIs. This integration enables near real-time visibility into the status of risks and barriers.

One of the most impactful features of a digitized PSM system is the use of dynamic bowtie visualizations. These tools present all aspects of risk, including hazards, threats, consequences, barriers, and escalation factors, in a clear, intuitive format. This makes it easier for teams to understand complex relationships, identify weak points, and take timely action. It also supports more consistent validation of safety decisions by providing a current and comprehensive view of operational risk.

What does this look like in practice?

Yara International, a global chemical manufacturer, offers a practical example of this approach. As part of its “Safe by Choice” initiative, the company implemented a digital permit-to-work system across nearly 30 sites. The results included faster permit approvals, fewer administrative errors, and an estimated 6,000 hours saved annually across 20 major locations. By aligning the system with site-specific workflows and terminology, Yara improved coordination between teams and reduced variability in non-routine task execution.

This case illustrates how digital tools can enhance the accuracy and relevance of safety information, reduce frontline exposure, and improve operational consistency. It also highlights the importance of designing systems that reflect the dynamic nature of risk and support continuous improvement.

Organizations that invest in connected, data-driven safety systems are better positioned to manage complexity, respond to emerging risks, and strengthen their safety culture. The goal is not only to digitize existing processes, but to enable better decisions through validated, real-time information.