Industrial organizations undertake various projects to effectively utilize their resources and increase efficiency in order to establish their position in competitive conditions. Improvements in maintenance operations also play a significant role in these projects. The effectiveness of maintenance programs in organizations is not only crucial for the efficient use of resources but also for the prevention of process accidents.
When examining process accidents on a global scale, deficiencies in maintenance programs emerge as underlying technical root causes. Equipment failures resulting from shortcomings in maintenance programs, delays in maintenance due to prioritizing production continuity, and equipment left in a faulty state all contribute significantly to the occurrence of process accidents.
According to the investigation report published by the HSE on the Buncefield Storage Depot accident in 2005, the apparent root causes were identified as failures in the level measurement system and high-level switch. However, the underlying root causes were categorized as follows:
- Incorrect identification of safety-critical equipment and inadequate maintenance practices
- Inadequate management system elements in tank filling
- Failure to adhere to procedures
- Excessive workload
- Culture of “Continuity of Operations” driven by economic reasons