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Sustaining and improving performance through audits and reviews

Sustaining and improving performance through audits and reviews

Having put an effective process safety management system in place it is important to review this on an ongoing basis to make sure it is working as intended and that it is still fit for purpose.

TÜV Rheinland supports auditing, performance measurement, incident investigation and Process Safety Management (PSM) systems review.

Auditing includes systems audits to confirm the PSM systems are still fit for purpose and have kept up with changes to operations, compliance audits to confirm that systems are operating as designed and ‘deep dive’ audits to confirm in detail that the key risk controls are being managed effectively.

Our services include:

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PSM system audits

TÜV Rheinland’s consultants are trained and extensively experienced in auditing arrangements for Process Safety Management (PSM).

We have used auditing as a tool for developing and improving process safety management systems, pragmatically establishing arrangements that provide a firm foundation for regulatory compliance and process safety performance improvement based on world-class practices.

Our auditing capability is founded upon a comprehensive suite of audit protocols based on those originally developed within ICI for its management level audits against its 'white book' SHE management system. The audit prompts cover a distillation of the global best practices in safety management recognized within ICI and extended to take due account of the requirements of the US OSHA standard for PSM, the requirements of the European 'Seveso III’ directive, and a broad experience of their application in conducting PSM audits of a variety of different companies, each with their own examples of good practice. TÜV Rheinland can draw on process safety experience from a wide range of industries, including oil & gas, chemicals, petrochemicals, pharmaceuticals, plus iron & steel.

TÜV Rheinland’s process safety assessment toolkit, ProSAT, has been developed for process safety auditors to use as an aid, both on a technical level as well as to facilitate the auditing process of operating organisations. Developed by TÜV Rheinland, the toolkit is used to assist process safety auditing carried out by TÜV Rheinland specialists.

Deep dive audits

This type of audit is focussed on high risk Major Accident Hazards (MAH) on a facility, and can be a complementary approach to PSM system audits, providing a targeted check on the integrity and effectiveness of the more critical parts of the PSM system that relate to the risk control systems of specific MAHs.

Bowtie analysis is used to identify safety critical risk control systems linked to a range of MAHs, and site based verification carried out to provide verification that these systems are working effectively.

Evidence is gathered on the ‘plant, process and people’ aspects of the risk control system, based on checks of facility records, discussions with people directly involved, and direct observation of the equipment, resulting in targeted recommendations for improvement.

Specialist technical audits

Specialist technical audits

Functional safety assessments

Functional safety assessments

Process Safety Performance Indicators (PSPI)

TÜV Rheinland offers a structured PSPI health check service to develop a set of key leading and lagging PSPIs for companies operating major accident facilities.

The methodology meets HSE guidance as outlined in HSG254 and other published guidance from CCPS and API.

The TÜV Rheinland approach uses an experienced site based team led by an independent and competent TÜV Rheinland specialist. Details on hazardous substances, major accident hazards and history of process safety incidents are used to identify weaknesses in risk control systems, from which leading and ‘SMART’ indicators are selected. TÜV Rheinland also provides help with the selection of appropriate lagging indicators to meet corporate reporting requirements.

Following the selection of leading and lagging PSPIs, TÜV Rheinland can provide further support as required to set up the monitoring systems, provide training, analyse results, periodically review and refresh the indicators, and set up a PSM system to manage the overall PSPI process on your site.

Incident investigation (RCA)

Incident investigation (RCA)

Bowtie analysis

Bowtie analysis

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