Guidelines for Auditing Process Safety Management Systems

A variety of approaches are given so the reader can select the methodology best suited. It discusses the fundamental skills, techniques, and tools of auditing, and the characteristics of a good process safety management system. And, since information needed for review in the audit may be scattered or undocumented, it offers suggestions on what to look for and where. Whether your company is large or small, whether you are experienced with auditing or just developing a system, consistent use of the techniques presented can significantly improve your audit and your process safety management.

Table of Contents:
List of Figures and Tables. Acronyms. Glossary. Preface. Acknowledgments. Introduction. Chapter 1. Management of Process Safety Management Systems Audits. 1.1 Overview. 1.2 Audit Program Scope. 1.3 Audit Frequency. 1.3.1 Degree of Risk. 1.3.2 Process Safety Management Program Maturity. 1.3.3 Results of Prior Audits. 1.3.4 Incident History. 1.3.5 Company Policies and Government Regulations. 1.4 Audit Staffing. 1.5 Audit Reporting. 1.5.1 Report Content. 1.5.2 Distribution of Reports. 1.5.3 Language of Reports. 1.5.4 Report Retention. 1.6 Audit Follow-Up. 1.7 Quality Assurance. 1.8 Summary. Chapter 2. Audit Techniques. 2.1 Overview. 2.1.1 Pre-Audit Activities. 2.1.2 Audit Activities. 2.1.3 Post-Audit Activities. 2.2 Audit Guides. 2.2.1 Protocol. 2.2.2 Questionnaire. 2.2.3 Topical Outline. 2.3 Gathering Data. 2.3.1 Data-Gathering Methods and Sources. 2.3.2 Interviewing Techniques. 2.3.3 Sampling Strategies and Techniques. 2.4 Evaluating Field Work. 2.4.1 Gathering Sufficient Information. 2.4.2 Determining Adequacy of Information Gathered. 2.5 Working Papers. 2.6 Summary. Chapter 3. Accountability and Responsibility. 3.1 Overview. 3.2 Indicators of Accountability and Responsibility. 3.2.1 Policy Statement. 3.2.2 Management Commitment. 3.2.3 Requirements for Procedures. 3.2.4 Individual Performance Measurement. 3.3 Organizational Changes. 3.3.1 Responsibilities. 3.3.2 Performance Measurement. 3.3.3 Resources. 3.3.4 Procedures. 3.3.5 Culture. 3.3.6 Acquisitions. 3.4 Summary. Chapter 4. Process Safety Knowledge. 4.1 Overview. 4.2 Audits of Process Safety Knowledge. 4.2.1 Data Sources. 4.2.2 Maintaining Information. 4.3 Types of Process Safety Information. 4.3.1 Chemical Data. 4.3.2 Design Data. 4.3.3 Design Basis. 4.3.4 Process Flow Diagrams. 4.3.5 Special Design Consideration. 4.3.6 Piping and Instrumentation Drawings. 4.3.7 Plot Plans. 4.3.8 Electrical Classification Plot Plan. 4.3.9 Plot Plan of Underground Services. 4.3.10 Equipment Specification Sheets. 4.3.11 Piping Specifications. 4.3.12 Safety-Critical Instrument Index. 4.3.13 Electrical One-line Diagrams. 4.3.14 Programmable Controllers and Computers. 4.3.15 Vendor Data. 1.3.16 Other Information. 4.4 Procedures. 4.4.1 Operating Procedures. 4.4.2 Other Procedures. 4.5 Enhancement of Process Safety Knowledge. 4.6 Summary. Chapter 5. Project Safety Reviews. 5.1 Overview. 5.2 Project Safety Review Procedures. 5.3 Hazard Analysis. 5.3.1 Hazard Analysis Techniques. 5.3.2 Staffing. 5.3.3 Roles/Responsibilities. 5.4 Recommendations/Follow-up/Closure. 5.4.1 Assigned Responsibility for Action Items. 5.4.2 Tracking System on Status of Action Items. 5.4.3 Resolution of Disagreements. 5.4.4 Updating Process Safety Information. 5.4.5 Report. 5.4.6 Dissemination of Findings. 5.4.7 Record Retention. 5.5 Summary. Chapter 6. Management of Change. 6.1 Overview. 6.2 Auditing Approach. 6.3 Written Procedures. 6.3.1 General Requirements. 6.3.2 Definition of Change. 6.3.3 Identification of Change. 6.3.4 Description of Change. 6.3.5 Temporary Changes. 6.3.6 Authorization. 6.3.7 Safety Review. 6.3.8 Training. 6.4 Documentation. 6.5 Summary. Chapter 7. Process Equipment Integrity. 7.1 Overview. 7.2 New Equipment Design, Fabrication, and Installation. 7.3 Preventive Maintenance. 7.4 Maintenance Procedures. 7.4.1 Work Authorization. 7.4.2 Safe Work Practices. 7.5 Contractors. 7.6 Decommissioning and Demolition. 7.7 Summary. Chapter 8. Process Risk Management. 8.1 Overview. 8.2 Hazard Identification. 8.2.1 Scope of the Study. 8.2.2 Methodology Selection. 8.2.3 Implementation Practices. 8.2.4 Study Recommendations. 8.3 Risk Assessment of Operations. 8.3.1 Scope of the Study. 8.3.2 Methodology Selection. 8.3.3 Implementation Practices. 8.3.4 Study Recommendations. 8.4 Risk Reduction Activities. 8.5 Residual Risk Management. 8.6 Customer/Supplier Facilities and Practices. 8.7 New Businesses. 8.8 Summary. Chapter 9. Incident Investigation. 9.1 Overview. 9.2 Incident Investigation System. 9.3 Reporting Mechanism. 9.3.1 Definition of Incidents. 9.3.2 Initial Reporting. 9.3.3 Responsibilities. 9.4 Investigation. 9.4.1 Criteria for Investigation. 9.4.2 Investigation Team. 9.4.3 Investigation Process. 9.5 Investigation Reporting 9.6 Dissemination of Findings. 9.6.1 Internal Distribution. 9.6.2 External Distribution. 9.7 Recommendation Implementation/Closure. 9.8 Incident Analysis. 9.9 Summary. Chapter 10. Human Factors. 10.1 Overview. 10.2 Organizational Issues. 10.3 Design Considerations. 10.4 Operating Culture. 10.5 Operating Procedures. 10.6 Environmental Conditions. 10.6.1 Lighting. 10.6.2 Noise. 10.6.3 Temperature. 10.6.4 Other Environmental Conditions. 10.7 Process Control Issues. 10.7.1 Display Design and Layout. 10.7.2 Alarms. 10.7.3 Match Between Operations and Programs. 10.7.4 Monitoring Multiple Screens. 10.8 Summary. Chapter 11. Training and Performance. 11.1 Overview. 11.2 Auditing of Training Programs. 11.2.1 Needs analysis. 11.2.2 Program Content and Presentation. 11.2.3 Training Frequency. 11.2.4 Training Records. 11.2.5 Training Program Effectiveness. 11.3 Summary. Chapter 12. Emergency Response Planning. 12.1 Overview. 12.2 Needs Analysis. 12.3 Emergency Response Plan Content. 12.4 Auditing Emergency Response Planning. 12.5 Emergency Management Systems. 12.6 Documentation of Resources, Organizations and Procedures. 12.7 Training and Records. 12.8 Emergency Response Plan Effectiveness. 12.9 Summary. Appendix A. Characteristics of an Incident Command. Bibliography. Index.

About the Author :
The CENTER FOR CHEMICAL PROCESS SAFETY (CCPS), an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has been a world leader in developing and disseminatinginformation on process safety management and technology since 1985. CCPS has published over 80 books in its process safety guidelines and process safety concepts series. For more information, visit www.ccpsonline.org.