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296 The requirements for audit and review are well established. The main issue is to ensure that
process safety is adequately included in audit and review programmes.
Guidance on auditing
297 Auditing provides an independent overview to ensure that appropriate management
arrangements (including effective monitoring) are in place, together with adequate risk control
systems and workplace precautions.
298 Various methods can achieve this. AIChE guidelines (
Guidelines for auditing process safety
management systems
119
and
Guidelines for technical management of chemical process safety
120
)
draw a distinction between process safety auditing, and process safety management systems
(PSMS) auditing.
299 The focus of process safety auditing is the identification and evaluation of specific hazards
(eg inspecting hardware and finding the absence of a relief device, or an independent trip system).
PSMS auditing, however, involves assessment of the management systems that ensure ongoing
control (eg the management systems in place to ensure that pressure relief devices have been
designed, installed, operated, and maintained in accordance with company standards).
300 Both types of audit are important. The process safety audit addresses a particular hazard
found at a specific time. It could lead to correction of the hazard without addressing the
underlying reason why the hazardous condition came to exist. The PSMS audit addresses the
management systems intended to preclude the creation of hazards.
301 The audit programme should include a selection of range of controls in place for preventing
or mitigating the risk of a Buncefield-type scenario. These include, but are not limited to:
commitment to process safety management;
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application of principles for safe management of fuel transfer;
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risk assessment procedures;
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effectiveness of process safety barriers;
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definition of roles and responsibilities;
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ensuring competence;
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assessment of staffing arrangements;
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management of fatigue associated with shift work;
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safety-critical communications, including shift handover;
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management of organisational change;
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management of contractors;
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retention of intelligent customer capability;
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retention of corporate memory;
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operational planning, and consignment transfer procedures;
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safety-critical operating procedures;
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provision of information;
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document control procedures;
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control of overrides/inhibits of safety-critical instrumentation systems;
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alarm systems;
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inspection and maintenance of safety-critical systems;
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permit to work and isolation arrangements;
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detection measures for loss of containment;
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integrity of secondary and tertiary containment measures;
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control of ignition sources;
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fire protection measures;
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management of plant and process changes;
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maintenance of records;
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active monitoring arrangements;
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reactive monitoring arrangements;
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