Many sites understand the value of individual safety studies, but often lack a cohesive process safety management system (PSMS) to unify their approach. At OTECSA Consulting Ltd, we help organisations develop and strengthen PSMS frameworks—starting with robust and effective process safety audits.
A PSMS provides a structured approach to managing process safety risks throughout a facility’s lifecycle—from initial design to daily maintenance. Each phase brings its own unique hazards, and an effective audit plan is key to evaluating how well these risks are being managed.
Why Process Safety Audits Matter
A strong process safety audit plan draws from:
- Site-specific performance data
- Applicable legislation (such as COMAH or DSEAR)
- Operational requirements
Audits must go beyond tick-box exercises. The Baker Panel Report (post-Texas City refinery explosion) highlights how ineffective audits can create a false sense of security, allowing critical risks to go unnoticed.
Independent audits bring:
- A fresh perspective
- Cross-industry experience
- Enhanced objectivity
What a Process Safety Audit Should Ask
An effective process safety audit answers three key questions:
- What should we do?
Are you following the latest standards, regulations, and good practices? - What do we say we do?
Are there written procedures in place that reflect best operational practice? - What do we actually do?
How does the site operate day-to-day, and are staff following the procedures?
Our Process Safety Audit Approach
Our expert team supports you by:
- Reviewing key documentation and performance records
- Conducting physical inspections of plant and equipment
- Interviewing frontline personnel to understand daily operations
This provides a comprehensive view of your site’s current safety culture and performance.
Ready to Strengthen Your PSMS?
Whether you’re looking for a one-off safety health check or a long-term audit plan, OTECSA can help. We provide objective insights that support continual improvement, reduce risk, and improve regulatory compliance.
Get in touch with our team today to discuss your process safety audit needs.