This week marks the first anniversary of the death of Professor Trevor Kletz, a pivotal figure in the profession and a man widely regarded as the father of industrial process safety. SHP looks back on a career spanning 70 years.
Trevor Kletz: the Godfather of process safety
Professor Trevor Kletz, who died on 31 October 2013, was one of the world’s foremost authorities on chemical process safety.
The recipient of the 2006 IOSH Lifetime Achievement Award, he has been credited with discovering solutions to the causes of some of the worst industrial disasters of modern times, including Bhopal and Piper Alpha (SHP January 2014, page 25).
Incredibly, Professor Kletz was 90
-years-old when he retired in 2012 after a distinguished career that spanned almost
70 years. During that time, he authored
14 books and over 100 peer-reviewed articles, often focusing on the lessons learned from accidents. He also penned an autobiography, By Accident… a Life Preventing Them in Industry.
The former chemistry graduate from Liverpool University first made an impact in the field of chemical engineering in 1944 when he joined the chemical giant ICI in its Billingham Division on Teesside.
It was here that he began his illustrious career in research before moving on to take on a series of production, technical and specialist management roles.
Along the way, he developed his pioneering perceptions and ideas on process safety.
Arguably, these reached fruition when he was appointed as the first division safety advisor in ICI’s Heavy Organic Chemicals (HOC) Division.
Much of the division’s business came from the use of hydrocarbon oxidation processes; Professor Kletz’s remit was to advise the design and operating staff on what actions he thought were necessary to bring about improvements.
As his longstanding and close ICI colleague Basil Eddershaw points out, Professor Kletz recognised that these processes were potentially hazardous and the actions played a pivotal role in developing ICI’s corporate risk culture, which not only guided the business but also influenced public thinking.
As part of this risk culture, he was instrumental in developing the Fatal Accident Frequency Rate (FAR), which was used in risk assessments (QRA) for existing and proposed business operations.
“QRA was of essential use in devising innovative and improved systems for
the reliable shutdown of hazardous processes,” explains Eddershaw. “Today, these are known
as High Integrity Protection Systems.”
Working closely with colleagues in ICI and also AEA from
the nuclear industry, Professor Kletz later developed the Fault Tree Analysis (FTA)
methodology and
its associated Hazard Analysis (HAZAN) technique.
More innovations followed, for example, the Hazard and Operability Studies (HAZOP). Another notable innovation was the ICI multi-stage procedures for hazard studies during a project’s life and its associated risk assessments, which were used to archive important documents and explained the reasons for the decisions taken.
Ian Wallace first came across
the professor when he was QHSE manager for Conoco, Northern North Sea. He remembers travelling to Teesside to learn about HAZOP and hazard identification (HAZID) and underlines their importance to the oil and gas industry.
“These techniques were rapidly adopted by the industry to evaluate the safety of new designs and modification of oil and gas production facilities,” he points out.
“They are frequently used to re-evaluate existing facilities to confirm the level of risk is still as low as reasonably practicable.”
Wallace is convinced that Professor Kletz’s concepts will continue to evolve and be pushed forward into new areas as safety professionals recognise their value and adaptability and make use of them in new fields.
“I know they are used for analysing electrical distribution systems, for safety studies in the railway, nuclear and aviation industries,” he explains.
“I can see value in developing them for many more novel high-risk activities such as medical operations and military
planning. As far as I can see,
the limit is our imagination and
ingenuity in working out how
to develop them.”
Early on in his career as a division safety advisor in ICI, Professor Kletz had recognised that other companies in hazardous industries would benefit from the process
safety innovations that he was developing and passionately believed that ICI should mutually share information, experience and practice.
As a result, he was instrumental in setting up the International Study Group
on Hydrocarbon Oxidation, a forerunner of the International Process Safety Group.
Such efforts were a major breakthrough in showing how open co-operation in the industry could be of mutual and lasting benefit.
In the 1980s, he left ICI and took up a research post at Loughborough University where he continued his innovative work, including research into computer-aided safe plant design.
Writing in a special anniversary issue of Loss Prevention Bulletin to mark his 90th birthday in October 2012, Paul Chung, Dean of School of Science at Loughborough University, credited him as a key contributor to “the idea of integrating safety application tools with computer-aided design (CAD) systems”.
Besides his research work at the university, Professor Kletz also worked for many years as an external member of the Sellafield Site Nuclear Safety Committee.
In the last 10 years of his life, he also became Adjunct Professor at the Mary Kay O’Connor Process Safety Center (MKOPSC), based in Texas A&M University’s Artie McFerrin Department of Chemical Engineering. Sam Mannan, MKOPSC Director and Regents Professor, underlines the valuable research that he undertook.
“Trevor Kletz had the uncanny ability
to look at complex processes and the risks associated with them and come up with very simple and actionable solutions,” he says.
“The impact of his work will be felt for years and decades to come. His seminal research contributions in process safety, inherent safety, and risk analysis are equal or greater than many other stalwarts in other fields.”
During his professional life, Professor Kletz was appointed an OBE in 1997 and awarded Fellowship of the Royal Academy of Engineering.
He also became a Fellow of the Institution of Chemical Engineers and the Royal Society of Chemistry and an Honorary Fellow of IOSH and the Safety and Reliability Society.
“Trevor was quite simply the outstanding figure of his time in making industry safer for all who work in it and the communities around it,” says David Brown, CEO at the Institution of Chemical Engineers.
“His work will certainly have saved lives. Every chemical and process engineering professional should follow his example
of commitment to process safety as a core principle – from the boardroom to every aspect of operations.”
HSE chair Judith Hackitt, a process engineer by background, paid tribute when he turned 90.
In the anniversary issue of Loss Prevention Bulletin, she said that many of the tough messages she continues to deliver to the UK’s major hazard industries are designed to reinforce the principles and lessons that she learnt from him.
As a process safety pioneer, Professor Kletz undoubtedly helped save lives and inspired others to do the same.
In her tribute to the late professor, Hackitt underlines his importance to safety professionals.
“Trevor made a huge difference to a lot of people in his lifetime. I am one of many engineers who was inspired by his commitment and enthusiasm for process safety always delivered in very clear and simple terms. The challenge now is for my generation
to ensure that Trevor’s passion for process safety is passed on to the next generations.”
SHP would like to thank Basil Eddershaw for generously assisting with background material for this article.
We would be interested to hear from readers who have their own recollections of working with Professor Kletz and his legacy. Please leave your comments below.
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Matt, an ergonomics and human factors expert, shares his thoughts on why MSDs are important, the various prevalent rates across the UK, what you can do within your own organisation and the Risk Management process surrounding MSD’s.
A great man, and a kind man, who was genuinely passionate about safety. I met him about 10 years ago, and was so impressed. Long may his work continue to inspire others. He is well remembered.
My sadness is that Trevor’s modesty prevented his family appreciating the extent, and impact, of his work during his lifetime….and sharing his triumphs. Your words and tributes, over the last year, offer both comfort and information to his family, thank you.
Trevor is greatly missed. A very generous man who was always willing to share his knowledge in the interest of others.