In 1974, a temporary 20-inch bypass pipe was installed to keep production running while a reactor was repaired. Then it failed under pressure, released 30 tons of cyclohexane, and killed 28 people.
1.Apply strict time limits to temporary changes - Set a hard expiration and a named owner.
2.Require the same hazard review for temporary work as permanent work - Production pressure is exactly when shortcuts feel justified and are most dangerous.
3.Confirm the people designing the change are qualified to design it - At Flixborough, the bypass was installed by personnel who weren't professionally qualified engineers.