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Risk assessment is the tool for maintaining perfect safety management systems and aiding sustainable process design, with hazard identification as the critical step. This step can be executed by past accidents analysis (PAA) to achieve the mentioned objectives. Despite of available analyses, the recurring of accidents identifies the shortcomings in PAA and requires a detailed examination as reported in this review. The intensified exploration of accident information will strengthen both the safety management system at existing facilities and process designing in terms of sustainability.

Pakistan is a developing country and has various chemical process industries to fulfill the local demands of numerous chemical products. In order to maintain the uninterrupted production from these industries, safety protocols need to be implemented. Safety progress must be studied with passage of time to identify the gaps and to decide the future actions. In this article, process safety in various chemical process industries (CPIs) of Pakistan is investigated regarding process safety management (PSM) and process hazard analysis (PHA). The covered industries include mainly fertilizer complexes, food processing plants, gas and oil processing plants, oil refineries, petrochemical plants, polymer processing plants, paper industries, tire industries, and sugar industries. This research will help in addressing the weaknesses. A comparative analysis of all considered CPIs is provided graphically. Overall analysis of all industries depicts that more emphasis on three categories is required, namely (1) documents upgradation and staff communication, (2) PHA revision and auditing, (3) PHA recommendations documentation and implementation. Provided suggestions, the implementation of PSM and PHA in Pakistan CPIs is expected to enhance, which may lead to a substantial increase in productivity of these industries without accidents.

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A general guideline to improve operational discipline is required. Operational discipline can be improved with simple things such as floor level meeting (FLM), job cycle check (JCC), risk assessment (RA), daily safety audit (DSA), consequence analysis (CA), mechanical integrity (MI), incident investigation (II), management of change (MOC), behavior observation (BO), pre-start up safety reviews (PSSR), process hazard analysis (PHA), job risk assessment (JRA), quantitative risk assessment (QRA), and process safety management (PSM) implementation. This article presents risks identified from floor level meetings, steps for job cycle check and risk sensitivity and procedure for daily safety audit and behavior observation audit. Consequence analysis, pre-start up safety review and why tree analysis are discussed for improving operational discipline. Inclusion of consequence analysis in work instructions is discussed.Procedure for accident investigation is elaborated by investigating trainee unit shift engineer (USE) burning injury accident and why tree diagram is constructed and findings and recommendations are provided. PHA techniques (HAZOP, Failure Mode and Effect Analysis) methodology is presented to enhance operational discipline. This article is especially for those industries which are located in countries where PSM implementation is not mandatory and they are lacking in operational discipline.