Guidelines for Auditing Process Safety Management Systems

Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 80 books in its process safety guidelines and process safety concepts series, and over 100 training modules through its Safety in Chemical Engineering Education (SACHE) series.

Acronyms. Glossary.

Acknowledgements.

Preface.

User’s Guide to the Second Edition.

Executive Summary.

Introduction.

Guidance for Chapter 3-24.

Process Safety Management Audit Programs.

1.1 Process Safety Management (PSM) Audits and Programs.

1.2 PSM Audit Program Scope.

1.3 PSM Audit Program Guidance.

1. 4 PSM Audit Frequency and Scheduling.

1.5 PSM Audit Staffing.

1.6 Certification of Auditors.

1.7 PSM Audit Criteria and Protocols.

1.8 Audit Reporting.

1.9 Audit Follow-up.

1.10 Quality Assurance.

1.11 Summary.

Conducting Process Safety Management Program Audits.

2.1 Audit Planning.

2.2 On-site Audit Activities.

2.3 Gathering, Recording, and Evaluating Audit Data and Information.

2.4 Post-Audit Activities.

2.5 Summary.

PSM Applicability.

3.1 Overview.

3.2 Audit Criteria and Guidance.

3.3 Audit Protocol.

Process Safety Culture.

4.1 Overview.

4.2 Audit Criteria and Guidance.

4.3 Posing Questions to Audit Process Safety Culture.

4.4 Audit Protocol.

Compliance with Standards.

5.1 Overview.

5.2 Audit Criteria and Guidance.

5.3 Audit Protocol.

Process Safety Competency.

6.1 Overview.

6.2 Audit Criteria and Guidance.

6.3 Audit Protocol.

Workforce Involvement.

7.1 Overview.

7.2 Audit Criteria and Guidance.

7.3 Audit Protocol.

Stakeholder Outreach.

8.1 Overview.

8.2 Audit Criteria and Guidance.

8.3 Audit Protocol.

Process Knowledge Management.

9.1 Overview.

9.2 Audit Criteria and Guidance.

9.3 Audit Protocol.

Hazard Identification and Risk Analysis.

10.1 Overview.

10.2 Audit Criteria  and Guidance.

103. Audit Protocol.

Operating Procedures.

11.1 Overview.

11.2 Audit Criteria and Guidance.

11.3 Audit Protocol.

Safe Work Practices.

12.1 Overview.

12.2 Audit Criteria and Guidance.

12.3 Audit Protocol.

Asset Integrity and Reliability.

13.1 Overview.

13.2 Audit Criteria and Guidance.

13.3 Audit Protocol.

Contractor Management.

14.1 Overview.

14.2 Audit Criteria and Guidance.

14.3 Audit Protocol.

Training and Performance Assurance.

15.1 Overview.

15.2 Audit Criteria and Guidance.

15.3 Audit Protocol.

Management of Change.

16.1 Overview.

16.2 Audit Criteria and Guidance.

16.3 Audit Protocol.

Operational Readiness.

17.1 Overview.

17.2 Audit Criteria and Guidance.

17.3 Audit Protocol.

Conduct of Operations.

18.1 Overview.

18.2 Audit Criteria and Guidance.

18.3 Audit Protocol.

Emergency Management.

19.1 Overview.

19.2 Audit Criteria and Guidance.

19.3 Audit Protocol.

Incident Investigation.

  20.1 Overview.

20.2 Audit Criteria and Guidance.

20.3 Audit Protocol.

Measurement and Metrics.

21.1 Overview.

21.2 Related Criteria.

21.3 Voluntary Consensus PSM Programs.

21.4 Audit Protocol.

Auditing.

22.1 Overview.

22.2 Audit Criteria and Guidance.

22.3 Audit Protocol.

Management Review and Continuous Improvement.

23.1 Overview.

23.2 Audit Criteria and Guidance.

23.3 Voluntary Consensus PSM Programs.

23.4 Audit Protocol.

Risk Management Programs.

24.1 Overview.

24.2 Audit Criteria and Guidance.

24.3 Audit Protocol.

Appendices.

Appendix A: PSM Audit Protocol.

Appendix B: PSM Audit Report Templates.

Appendix C: Sample PSM Audit Certifications.

Appendix D: PSM Audit Plan Templates.

Appendix E: Interview Questions for Nonmanagement Personnel.

Appendix F: PSM Audit Planning Questionnaire.

Appendix G: Integrated Contingency Plan (ICP) Audit Protocol.

Appendix H: International PSM Audits.

Appendix I: PSM Audit Dilemmas.

Appendix J: PSM Audits During Mergers and Acquisitions.

Index.