Common Process Safety Audit Findings

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Process safety audits are conducted for two main reasons:

  • Provide feedback on process safety program implementation and effectiveness to identify improvement opportunities
  • Ensure compliance with process safety regulations such as OSHA 29 CFR 1910.119 (Process Safety Management) and EPA 40 CFR 68 (Risk Management Program)

While some facilities view compliance as the primary purpose, the real value lies in using audits to strengthen overall process safety performance. For facilities covered by these regulations, compliance audits are required at least every three years. Many facilities have now conducted 7–9 audits since the OSHA rule was promulgated in 1992.

A review of audit findings shows that certain issues continue to appear repeatedly across different process safety elements. This five-part series highlights some of the most common findings and provides practical guidance to address them or prevent them from happening in the first place:

  1. Operating/Safe Limits Table Issues
  2. Operating Procedure, Safe Work Practice, and Training Issues

  3. Mechanical Integrity Issues

  4. Process Safety Information and Process Hazards Analysis Issues
  5. Other PSM Elements

The authors – Jim Klein, Jim Thompson, and Scott Dean – have done hundreds of process safety audits. Jim Klein and Jim Thompson are also AIChE Fellows and certified process safety auditors (retired).

References

The published versions of these articles can be found on Chemical Processing’s website where you can also access more tools and resources to help you run safe, efficient facilities.

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