What are the most important items to include in a process safety audit checklist?

1 Management commitment

The first item to include in a process safety audit checklist is the level of management commitment and leadership for process safety. The auditor should evaluate how the senior management communicates and demonstrates the importance of process safety to the plant personnel, how they allocate resources and responsibilities for process safety, how they monitor and review the process safety performance, and how they foster a positive and proactive safety culture. The auditor should also check if the plant has a clear and documented process safety policy, vision, and objectives, and if they are aligned with the corporate and regulatory requirements.

2 Hazard identification and risk assessment

The second item to include in a process safety audit checklist is the effectiveness of the plant's hazard identification and risk assessment processes. The auditor should verify if the plant has identified all the potential hazards and scenarios that could lead to a major incident, such as process deviations, equipment failures, human errors, external events, or sabotage. The auditor should also check if the plant has conducted a comprehensive and systematic risk assessment for each hazard, using appropriate methods and criteria, such as HAZOP, LOPA, or QRA. The auditor should also review if the plant has documented and updated the risk assessment results, and if they have communicated them to the relevant stakeholders.

3 Control measures and safeguards

The third item to include in a process safety audit checklist is the adequacy and reliability of the control measures and safeguards that the plant has implemented to prevent or mitigate the consequences of a major incident. The auditor should examine if the plant has applied the hierarchy of controls, which prioritizes elimination, substitution, engineering, administrative, and personal protective measures, in that order. The auditor should also inspect if the plant has designed, installed, operated, and maintained the control measures and safeguards according to the best practices and standards, such as alarms, interlocks, relief valves, emergency shutdown systems, fire protection systems, or emergency response plans. The auditor should also test if the control measures and safeguards function as intended, and if they are periodically verified and audited.

4 Training and competence

The fourth item to include in a process safety audit checklist is the competence and awareness of the plant personnel regarding process safety. The auditor should assess if the plant has identified the process safety competencies and training needs for each role and task, and if they have provided adequate and relevant training and education programs. The auditor should also evaluate if the plant has verified and recorded the competence and qualification of the personnel, and if they have provided refresher and update training as needed. The auditor should also observe if the personnel demonstrate knowledge and understanding of the process safety hazards, risks, and controls, and if they follow the procedures and instructions correctly.

6 Audit and review

The sixth and final item to include in a process safety audit checklist is the quality and frequency of the plant's own audit and review processes. The auditor should verify if the plant has conducted regular and comprehensive internal audits and inspections to evaluate the compliance and effectiveness of the process safety management system, and if they have used qualified and independent auditors and inspectors. The auditor should also confirm if the plant has reported and communicated the audit and inspection results, findings, and recommendations to the management and the personnel, and if they have addressed and resolved any gaps or issues identified. The auditor should also ensure that the plant has reviewed and updated the process safety management system and objectives based on the audit and inspection outcomes, and any changes in the plant's operations, environment, or regulations.