As we enter 2025, the landscape of process safety management (PSM) is becoming increasingly complex. Ageing infrastructure, climate challenges, and the push for sustainability are just a few factors reshaping priorities. Looking at each in turn, these are our top 10:
1. Ageing Infrastructure: A Risk That Can’t Be Ignored
Industrial plants worldwide are ageing, with many facilities operating beyond their intended design life. Maintenance backlogs and deferred investments increase the risk of failures.
The UK’s Health and Safety Executive (HSE) cited ageing equipment as a recurring factor in major incidents, emphasising the importance of robust asset integrity management.
Post-pandemic recovery has exacerbated maintenance backlogs, as identified in a 2023 Deloitte Survey, making this a pressing issue for 2025. Companies have published information about the inroads they are making in this area, such as:
- rigorous asset integrity programmes, combining predictive maintenance tools and routine inspections to manage risks effectively.
- highlighting their investment in retrofitting older facilities with modern safety systems to ensure compliance and reduce the likelihood of incidents; and
- using advanced inspection technologies like drones and AI-driven analysis to assess the structural integrity of ageing infrastructure, minimising downtime and enhancing safety.
In the chemical sector, sustainability goals are increasingly intertwined with PSM practices. Companies are integrating process safety strategies into broader sustainability frameworks,
Equally, the drive to net zero is accelerating the adoption of new technologies, such as hydrogen and battery storage, which often introduce new hazards into facilities previously unexposed to such risks. These innovations require careful consideration of process safety to prevent incidents and manage the transition effectively.
The push for hydrogen and battery integration in industrial processes demands a new layer of competency. Managing the transition involves:
- developing specialised training programmes to upskill workers in handling these emerging technologies
- implementing rigorous hazard identification and risk assessment procedures tailored to hydrogen and battery systems.
- collaborating with industry bodies to standardise safety protocols for these technologies and ensure consistent application across facilities.
Integrating safety into sustainability ensures organisations can achieve their environmental goals without compromising operational safety.
3. Addressing Workforce Competency and Human Factors
The chemical industry faces a dual challenge: addressing skill gaps in an evolving workforce and managing human factors that contribute to safety incidents. Research shows that 41% of safety failures are due to human factors, such as inadequate training or cognitive overload.
Some examples of how companies have sought to overcome this are:
- developing comprehensive safety training programmes, including advanced simulators and virtual reality (VR) modules, providing employees with realistic, hands-on experience in identifying and responding to process hazards.
- offering modular safety training programmes tailored to different job roles, ensuring that employees receive targeted and relevant training; and
- implementing a behavioural safety programme that encourages open communication about risks, fostering a culture where employees feel empowered to report hazards and suggest improvements.
A commitment to both competency and culture is a continual requirement to address human factors effectively.
4. Digital Transformation: Opportunity and Risk
Technologies like IoT, AI, and real-time monitoring are transforming PSM. Predictive analytics can anticipate equipment failures, saving millions annually in downtime costs.
However, this reliance on technology introduces cybersecurity vulnerabilities.
- The 2021 Colonial Pipeline ransomware attack serves as a stark reminder of the need for robust cybersecurity measures integrated into digital safety systems.
- Another notable example is the Pipedream malware toolkit, publicly disclosed in 2022. This sophisticated framework is designed to target programmable logic controllers (PLCs) and industrial control systems, enabling attackers to scan for, compromise, and control specific ICS/SCADA devices. Its modular architecture allows for highly automated exploits, posing significant risks to critical infrastructure.
- Additionally, in 2024, the Ransomhub group executed a ransomware attack on the industrial control systems of a Spanish bioenergy plant. This incident underscores the vulnerabilities within ICS environments and the increasing focus of cybercriminals on critical infrastructure sectors.
These incidents highlight the evolving cyber threat landscape facing industrial control systems, emphasising the need for organisations to implement comprehensive cybersecurity strategies alongside their digital transformation efforts.
5. Preparing for Climate-Driven Events
Extreme weather events, from floods to hurricanes, are becoming more frequent and severe. The UN Climate Conference (COP29) emphasised the importance of embedding climate resilience into safety systems.
In the UK and Europe, increasing extreme weather demands greater consideration in risk assessments, including rising sea levels, flood risks, and extreme weather impacts, to ensure operational continuity in vulnerable locations.
6. Rising Regulatory Pressures
Governments are tightening PSM regulations in response to high-profile incidents. For global operators, consideration needs to be given to OSHA’s revision of its PSM standards. Staying ahead of these changes ensures compliance and avoids costly enforcement actions.
7. Leveraging Advanced Technologies for Safety
Emerging technologies like digital twins and AI-driven maintenance tools are game-changers.
Digital twins enable operators to simulate and test safety protocols in a virtual environment, improving preparedness and reducing risks. The pilot project undertaken and reported on by Siemens showed a 20% reduction in safety incidents at a chemical plant by using digital twin simulations.
8. Supply Chain Vulnerabilities
The COVID-19 pandemic and geopolitical tensions have exposed vulnerabilities in global supply chains. For PSM, delays in safety-critical materials or equipment can increase risks. Companies are diversifying suppliers and maintaining strategic stockpiles to ensure business continuity.
9. Knowledge Retention: The Power of Experience
With a significant portion of the industrial workforce nearing retirement, retaining institutional knowledge is critical and requires real planning and management. Mentorship programmes and digital knowledge repositories are excellent examples of how companies can capture and transfer safety insights to new generations.
10. Transparency and Stakeholder Trust
Stakeholders, from regulators to investors, are demanding greater transparency. Publishing safety data in sustainability reports is becoming standard practice, meaning that the creation and reporting of process safety metrics helps to demonstrate commitment to both safety and sustainability.
Looking Ahead to the key Process Safety Challenges for 2025
2025 presents both challenges and opportunities for process safety management. Companies that proactively address these issues—leveraging technology, enhancing skills, and embedding safety into sustainability goals—will be better positioned to navigate this dynamic landscape.
To talk to us about how we can help meet some of your 10 Key Process Safety Challenges for 2025, click below!