
In this Insights episode of the Oil & Gas Journal ReEnterprised podcast, downstream editor and lead reporter Robert Brelsford talks with Joe Barnes, principal of Barnes’ Engineering Consultants and a veteran oil and gas operations, maintenance, reliability, and major-projects leader with more than 30 years of industry experience.
Barnes, who spent roughly half of his career in refining and half in exploration and production, discusses why process safety management must remain a central concern for everyone working in oil and gas—not only safety professionals. Drawing on his experience with a major refinery accident and the aftermath of a separate major offshore incident, Barnes explains why good intentions are not enough to prevent major incidents, particularly in times when the potential for high margins could tempt operator’s into promoting maximized production over execution of maintenance on processing and production installations to ensure safe and reliable operations.
During the conversation, Robert and Joe examine recurring root causes identified through Barnes’ review of process-safety incidents dating back to the mid-1980s, including absence of leadership, poor communication, inadequate risk identification and mitigation, aging equipment, deferred maintenance, workforce turnover, and the loss of experienced personnel. They also discuss why the industry has sometimes failed to consistently share and apply lessons from previous incidents, particularly when investigation findings are not widely accessible.
The two consider the difference between personal safety and process safety metrics, the warning signs that preceded the 2005 BP Texas City refinery explosion, and the role of management of change (MOC) in evaluating staffing, maintenance, turnaround, efficiency, and capital-reduction decisions. Barnes also outlines the questions boards and executive leaders should be asking to ensure that process safety remains a business priority across economic cycles.
Robert and Joe further explore how refineries can use past incident scenarios as practical training tools, strengthen external oversight and auditing, encourage employees and contractors to report weak signals and near misses, and build a process-safety culture that rewards risk identification and mitigation. Barnes closes with recommendations for protecting critical maintenance, communicating expectations clearly, auditing what matters, and keeping people at the center of process safety decision-making.





















