Process Safety with Trish & Traci Henry David Thoreau of Process Safety – Trevor Kletz
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Oct 14, 2025 Trevor Kletz transformed process safety with revolutionary HAZOP advocacy and intrinsic safety principles. His approach highlights the importance of learning from accidents and simplifying designs to avoid complexity. The hosts discuss how Kletz shifted the focus from blaming human error to creating resilient systems. They also dive into the significance of storytelling in organizational memory and encourage a return to basic design principles for safer outcomes. Kletz’s legacy continues to inspire safety practices and innovations.
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Power Of Structured HAZOP Reviews
- HAZOP is a structured method that forces designers to examine every line and permutation of a process using guide words.
- Trevor Kletz championed HAZOP's broad application across control, procedures, and systems to reveal hidden hazards.
Design For Inherent Safety First
- Eliminate, minimize, substitute, moderate, and simplify hazards during design rather than adding downstream controls.
- Build inherent safety into the process so you avoid relying on alarms or shutdowns as primary protections.
Design Around Human Fallibility
- Human error is inevitable, so blaming operators is unhelpful and nonconstructive.
- Instead, engineer resilient systems so mistakes do not lead to catastrophic outcomes.
