What Are the Biggest Challenges in Process Safety Management Today?

Process Safety Management (PSM) is a vital part of maintaining safe, reliable, and compliant industrial operations.

As industries evolve and technology advances, the challenges involved in keeping people and processes protected continue to grow. From regulation to culture, every organisation must manage these pressures carefully to maintain effective process safety.

Keeping Up with Regulation and Standards

One of the most persistent challenges is keeping pace with changing regulations and safety standards. Updates to legislation, industry guidance, and international frameworks require businesses to regularly review and update how they operate. 

Aligning with UK Health and Safety Executive (HSE) expectations, the Control of Major Accident Hazards (COMAH) regulations, and standards such as IEC 61511 and ISO 45001 demands both time and expertise.

For older facilities, compliance can be particularly demanding. Many plants were designed decades ago, long before today’s safety expectations. 

Adapting those systems to meet modern requirements often involves investment in new safeguards, documentation, and training. Businesses that fail to keep up risk financial penalties, legal consequences, and lasting reputational damage.

The Skills Gap in Process Safety

The shortage of experienced process safety professionals continues to affect industries across the UK. As senior engineers retire, many organisations are struggling to replace the depth of technical and regulatory knowledge needed to manage complex safety systems.

Without strong internal expertise, safety responsibilities can fall between departments. Building capability through training, mentoring, and structured knowledge transfer is essential. 

A lack of skilled personnel can leave significant risks unidentified or poorly controlled, creating weaknesses that are difficult to address once operations are underway.

Integrating Safety from the Start

Process safety should never be introduced as an afterthought, yet too often it is considered only once designs are complete. When safety is added late, hazards may already be built into the system, leading to costly redesigns or operational challenges that could have been avoided.

Integrating safety from the beginning of the project ensures that hazards are identified early and either removed or managed before construction begins. 

Collaboration between process engineers, designers, and safety specialists helps achieve safer, more efficient operations and reduces risk at every stage.

Growing Complexity and Digitalisation

Modern industrial processes are increasingly complex. Automation, digital control systems, and advanced data monitoring now form part of everyday operations. While these technologies improve efficiency, they also introduce new forms of risk.

Failures in connected systems can cascade quickly, and faults in software or instrumentation can have consequences just as severe as mechanical failures. 

Cybersecurity is now an additional concern, as networked control systems may be exposed to external threats. Effective process safety management must account for both traditional engineering hazards and those introduced by digital technology.

Managing Change Effectively

Industrial plants and engineering projects are constantly evolving. New feedstocks, process adjustments, and equipment changes can all alter the risk profile of an operation. 

When modifications are made without proper review, or when updated procedures are not communicated effectively, process safety can deteriorate over time.

A structured management of change process ensures that every modification is assessed for its safety implications before being implemented. It also keeps documentation accurate and aligned with real operating conditions, preventing small inconsistencies from becoming larger risks.

Measuring Performance and Continuous Improvement

Another challenge lies in understanding whether process safety systems are truly effective. Many organisations rely on reactive indicators such as incident statistics, but these show only where problems have already occurred. 

Leading indicators, such as maintenance completion rates, safety-critical testing, and training compliance, provide a more accurate picture of ongoing performance.

Collecting and reviewing this information supports continual improvement and helps to identify potential weaknesses before they cause harm. 

A clear reporting culture, where employees can raise concerns and share lessons learned, is essential for maintaining control and promoting long-term improvement.

Building a Strong Safety Culture

Even with advanced systems in place, the success of process safety depends on people. A strong safety culture encourages open communication, consistent training, and shared accountability. 

When employees understand the reasons behind procedures and feel confident to raise issues, risks are identified sooner and managed more effectively.

Cultural challenges often arise when production targets are prioritised over safety or when staff fear blame for reporting mistakes. Leadership plays a vital role in setting expectations, allocating resources, and showing that safety is never compromised. 

When everyone in an organisation takes ownership of safety, incidents become less frequent and operations more resilient.

There are several frameworks available to help structure Process Safety Management. Here are some examples:

• The Energy Institute: Process Safety Management Framework

• The Occupational Safety and Health Administration: Process Safety Management of Highly Hazardous Chemicals

• The Center for Chemical Process Safety: Risk-Based Process Safety Model

• The International Association of Oil & Gas Producers: Process Safety Fundamentals
  

Why These Challenges Matter

Neglecting process safety can have serious consequences. As explored in our article on how process safety failures impact engineering projects, the results can include serious harm to people, damage to the environment, financial loss, and lasting reputational impact.

Addressing these challenges requires both technical expertise and cultural commitment. Regular reviews, clear communication, and consistent training are essential to keeping systems strong and effective.

At 6 Engineering, we work with businesses to identify hazards, assess risks, and implement reliable safety systems. Our engineers provide practical, evidence-based consultancy across risk assessment, HAZOP facilitation, and process safety management reviews. We help organisations meet modern safety expectations and strengthen operational performance.

To find out how we can help you improve your process safety management and prevent costly failures, contact our team today.