Managing Risk and Reliability of Process Plants

Appendix D: An Illustrative Audit Checklist for Process Safety and Reliability [Structured Around Hawksley's Six Principles]

1. INTRODUCTION

This checklist can also be used as an aide-memoire when considering what should be included in routine monitoring of plant safety and reliability. The checklist can be edited to suit the particular type of plant or operation being audited, and expanded into the form of a worksheet with sufficient space for comments.

(Note: The checklist is designed to illustrate broad principles. For any specific plant the audit checklist should be tailored, perhaps using this checklist as a starting point, to match the plant-specific hazards and potential sources of unreliability.)

If the plant being audited is unfamiliar to the auditor, or if the auditor wishes to test the plant manager's understanding of the hazards, it is helpful to discuss both (a) the factors introducing the potential for an incident and (b) the possible severity of such an incident with the plant manager (i.e., Sections 2 and 3) before continuing with the later topics. This helps the auditor recognize the sections of the plant, and the software, that most need attention.

[1]This also draws on unpublished work by D. Drewitt.

2. SUMMARY OF INHERENT HAZARDS

Discussing these with the plant management achieves two principal goals:

  • it helps the auditor to identifying those plant sections and features that introduce a likelihood of an incident; and

  • the understanding displayed of these by plant management reveals how well the 1st Hawksley requirement is met)

2.1

Raw Materials, Intermediates, and Products (with Inventories).

  • Flammables:

  • Explosive:

  • Unstable:

  • Toxics:

  • Environmentally...

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