Process Safety Audit

Process Safety Audit

Process Safety Audit

Industries which handle large quantities of hazardous substances are required to demonstrate their capability to design, locate, operate and maintain facilities to standards acceptable to the Govt. and public.

There is no single ideal system of Hazard identification procedures. Among the tools available for occupiers and managers of hazardous installations to check and reassure the effectiveness of procedures and methods followed on safety, the most useful tool is Safety Audit. Health and Safety Executive of UK defines Safety Audit, “as the structured process of collecting independent information on the efficiency, effectiveness and reliability of the total health and safety management system and drawing up plan for corrective action”.

Safety Audit is normally carried out by an outside team and will examine all facilities and activities of an organisation from the angle of process safety, assess the current level of prevention, protection and emergency management preparedness and subsequently prepare an action plan to upgrade safety inputs to avert mishaps and limit consequences.


  • Identifies system deficiencies from safety point of view,
  • Assess the potential process hazards,
  • Identifies measures to minimize the hazards,
  • Recommend proper measures & procedures for controlling the identified hazards
  • Recommend measures for improving the effectiveness of the existing process conditions.


Stage 1: Pre-Audit Activities

  • Collection of necessary documents (List will be given by us in advance)
  • Customized Questionnaire/checklist shall be prepared considering the company’s facility, guidelines for process safety and audit objectives.
  • Preparation of AUDIT PLAN (Audit Plan shall be proposed by us, which shall be discussed with you and finalized)

Stage 2: Audit

  • The field visit will be carried out as per the Audit plan.
  • Unsafe conditions/practices shall be identified from process point of view.
  • Specific risks due to quantity of solvents or hazardous chemicals stored/used in process shall be identified.
  • Verification of the documents with shop-floor conditions shall be carried out.
  • Audit team shall conduct interactions with employees and contract workers to evaluate their personnel competencies,
  • Process Hazards shall be identified & evaluated,
  • To identify the activities that can lead to major fires, explosions and toxic releases which will have both onsite and off site consequences.
  • The availability, adequacy and efficacy of existing fire fighting facilities w.r.t. identified hazards, shall be evaluated.
  • Evacuation Plan & Evacuation Route to Assembly point shall be reviewed.

Stage 3: Closing Meeting

  • The closing meeting shall be arranged to share Strengths, Gaps, Opportunities and Recommendations.

Stage 4: Submission of Final Report

  • A draft report will be submitted for your review and approval.
  • On approval of the draft report, final report will be prepared and submitted to you.

Benefits of Safety Audit are:

  • Identifies loss producing events,
  • Assess the potential losses associated with the risk,
  • Identifies measures to minimize the losses,
  • Identifies system deficiencies.