Inherently Safe Design Practices: A Necessity for Chemical Industry Projects

By Dr. Manoj Ravsaheb Kadam

Safety in the chemical industry is often perceived as a layer added after the design and construction of a plant. However, true safety lies in an inherently safe design, where potential hazards are minimized at the root rather than controlled later with protective measures. A powerful analogy to understand this is the difference between a natural hand and an artificial hand. A hand by birth is structurally and functionally integrated into the human body, making it efficient and safe. An artificial hand, though functional, comes with limitations and adjustments, much like adding safety features post-plant construction instead of designing them from the beginning.

The Essence of Inherently Safe Design

Inherently safe design is a proactive approach to safety in chemical plants. Instead of relying on complex safety systems, the process itself is designed to eliminate or significantly reduce hazards. The core principles include:

1. Minimization – Reducing the quantity of hazardous materials used in a process.
2. Substitution – Replacing hazardous chemicals with safer alternatives.
3. Moderation – Operating at safer conditions (e.g., lower temperatures and pressures) to prevent extreme reactions.
4. Simplification – Designing processes to be straightforward and fail-safe, reducing the chances of human error.

Practical Experience: Learning from the Field

During my extensive experience in chemical and pharmaceutical plant design, I have encountered numerous cases where the lack of inherently safe design led to costly modifications and risks. One particular project stands out.

A client sought our consultancy after facing repeated solvent vapor leaks in their facility. The plant had been designed with safety interlocks, sensors, and emergency venting systems—yet incidents persisted. Upon analysis, we identified that the issue stemmed from the high volatility of the solvents used and the complex piping layout that made leak detection challenging. Our solution? Instead of adding more safety layers, we re-engineered the process:

• Substituted the solvent with a less volatile alternative.
• Reduced the volume of solvent in circulation.
• Modified the layout to eliminate unnecessary piping and junctions.

The result was a safer, more reliable system with fewer maintenance concerns and long-term operational efficiency.

S V Engineering and Consultancy: Commitment to Safety

S V Engineering and Consultancy Services (SVECS) focuses on inherently safe design practices and has successfully completed over 150 projects. Remarkably, there has not been a single incident or accident in any facility designed by SVECS. Our design philosophy integrates safety at every stage, ensuring that operational hazards are minimized without compromising efficiency or productivity.

We have worked with leading organizations in the chemical and pharmaceutical industries, providing state-of-the-art engineering solutions that prioritize worker safety and environmental sustainability. Our extensive expertise in process safety, risk assessment, and hazard mitigation makes us a trusted partner for companies looking to build world-class, incident-free facilities.

For more information, visit our website: www.svecs.com.

The Artificial Hand vs. the Natural Hand Analogy

This case highlights the core philosophy of inherently safe design. Had the plant been designed with these principles from the start, the company would have saved significant costs and mitigated risks earlier. Just as an artificial hand—though useful—is a compensation for a natural hand, late-stage safety modifications can never fully replace an inherently safe design. By designing safety into the process from the beginning, industries can avoid the financial and operational burdens of retrofitting safety measures later.

Benefits of Inherently Safe Design in the Chemical Industry

• Cost Savings: Reducing the need for expensive safety equipment and emergency response systems.
• Operational Efficiency: Eliminating unnecessary complexities and reducing downtime due to safety incidents.
• Environmental Protection: Minimizing the risk of hazardous emissions and spills.
• Regulatory Compliance: Ensuring adherence to national and international safety standards.
• Worker Safety: Creating a safer environment with reduced exposure to hazardous substances.

Conclusion: The Future of Safety in Chemical Industry Projects

For the chemical industry, safety should not be a reactive measure but an intrinsic part of the design. My goal as an entrepreneur, engineer, and consultant is to advocate for inherently safe design principles so that future projects do not have to retrofit safety but instead integrate it from the very beginning.

With increasing regulatory scrutiny and the growing importance of sustainability, inherently safe design is no longer an option but a necessity. Industries that embrace this philosophy will not only reduce risks but also gain a competitive edge by ensuring operational excellence and long-term safety.

By embracing these practices, we ensure that our plants are not just compliant with regulations but are also sustainable, efficient, and truly safe for workers, communities, and the environment.