There is a great deal of evidence in the literature about modifications made in chemical plants that have eventually caused serious accidents with often catastrophic consequences. The most notorious and well-studied case is the Flixborough accident, which occurred in England in 1974, which resulted in the total destruction of the plant and the deaths of 28 operators, as well as casualties and destruction in the neighbour community. The official investigation report states that “the disaster was caused by the introduction of a modification that destroyed the integrity of a plant that had been very well designed and built.”
Minor modifications, most often done with the best of intentions, can result in disaster. The constant technological development is part of our daily life and imposes constant adaptations and modifications in our manufacturing processes in relation to machines, equipment, products handled, manufacturing process itself, etc. In this way, it is essential that every company has a system to control the modifications introduced in their operating routines, to ensure that these modifications have been properly evaluated so that there will be no introduction of additional unidentified risk.
This topic addresses, among other things:
- Definition of “Modification”.
- The different types of Modification: Operating Conditions and Processes, Products, Administrative, Equipment, etc.
- Evaluation and Authorization Group.
- Check-List Modification.
- Link between Modification and Work Permit.
- Study of accidents caused by modifications.
