AI: Improved Process Safety or Increased Risk?
What does AI bring to process safety, and what risks does it introduce?
Artificial Intelligence (AI) is everywhere — from chatbots to self-driving cars. In the process and energy industries, it’s emerging in plant operations, predictive maintenance, and even safety management. But before we imagine robot operators or automated HAZOPs, we need to ask: what does AI actually bring to process safety — and what risks does it introduce?
At its core, process safety is about making better decisions under uncertainty. We use hazard analyses, operating procedures, mechanical integrity programs, and emergency planning to reduce the likelihood and impact of major accidents. AI can enhance these tools by detecting patterns in large datasets, predicting equipment failure, and suggesting operational adjustments in real time.
For example: thousands of refinery instrument readings stream in. A human operator may catch obvious anomalies, but subtle trends may slip by. An AI model, trained on years of historical data, could flag those small deviations before they become critical failures. That is the promise of AI: sharper foresight and more informed decision-making.
AI is not a magic bullet. Models are only as good as the data they are trained on, but rare, catastrophic events are rarely captured in any dataset. Black-box algorithms may also deliver recommendations without explanations, leaving operators unsure whether to trust them. Perhaps the greatest danger is false confidence; organizations might lean on AI while cutting back on the human expertise and robust processes that make systems resilient.
Here’s another example: an operations superintendent uses AI to write a complicated startup procedure. One of the steps in that procedure states, ‘Open hydraulically operated valve H-100’. In fact, the statement should have been, ‘Close hydraulically operated valve H-100’. An operator follows the procedure, the wrong valve position is set, and a major release occurs.
AI has increased the overall risk.
A New Series
Given this background, we are launching a new series of posts on the topic ‘AI and Process Safety’. We will explore how AI intersects with every stage of the safety lifecycle: hazard identification, process design, operations, maintenance, incident learning, and human factors. Each post will highlight practical applications, real-world examples, and the limits of what AI can (and cannot) do.
Potential topics are:
Why AI Matters for Process Safety
AI in Hazard Identification
AI in Design
AI in Operations and Control
AI in Asset Integrity and Maintenance
AI in Incident Analysis
AI in Human Factors
The Future of AI in Process Safety
Like it or not, AI is coming to process safety. The horse is out of the barn. The question is whether we will use it wisely — or whether it will become just another risk to manage.
Earlier Posts
We have already explored aspects of AI in process safety in earlier posts. They are listed below. As time permits, we will merge, edit and delete these old posts.
Foundations & Theory
Practical Applications
Management
Risks & Limitations
Case Studies & Stories
