AUDIT PURPOSE

  • The purpose of the audit was to :

    1. Confirm the key preventative and mitigating control measures as identified within the Safety Case are present and maintained.
    2. Confirm the identified control systems are subject to regular testing, inspection and maintenance activities.
    3. Where necessary identify corrective actions, and make suggestions to improve the management of e control measures & control systems.

AUDIT SCOPE

  • There are 16 Critical Control Summary Sheet (CCSS) that represent the 16 classes of control measures identified for the relevant Safety Case. Individual control measures are allocated to one of these groups. Each group has a performance measure (PM) and a critical control protocol (CCP) associated with it. The PM set the required performance from the control measures and the CCP provides the guidance on how that performance cm be determined.

AUDIT ELEMENTS

  • CCSS 01 Safe Work Permit

  • CCSS 02 Emergency Management

  • CCSS 03 Control of Ignition Sources

  • CCSS 04 Pressure Relief System

  • CCSS 05 Procedures and Training of Bulk LPG Tanker Drivers

  • CCSS 06 Training of Terminal Operators

  • CCSS 07 Emergency Shutdown

  • CCSS 08 Cylinder Filling and Inspection Procedures & Training

  • CCSS 09 Design of Equipment

  • CCSS 10 Fixed Fire Fighting System

  • CCSS 11 Traffic Management

  • CCSS 12 Inspections & Monitoring

  • CCSS 13 Training Maintenance Personnel

  • CCSS 14 Procedures and Training of Bulk LNG Tanker Drivers

  • CCSS 15 Process Shutdown System

  • CCSS 16 Documentation Systems

METHODOLOGY

  • The audit focused on the CCSS noted in the preceding section, using the CCP for each of the CCSS, and through a combination of document review, functional tests and visual examination, information against the components were obtained, where available.

    For the purposes of this audit, the level of compliance will be graded as follows:

    Fully Compliant (Fully) - Full compliance to audit criteria

    Opportunity for Improvement (OFI) - A borderline NC that suggests the need for an improvement action

    Non Compliant (NC) - Non conformance to audit criteria

Critical Control Protocol 01: SAFE WORK PERMIT

  • Was this element covered during this audit

COMPETENCY and TRAINING

1.1 Technical Information

  • Sample Operations Training & Competency records to confirm training in Safe Work Procedure, including:
    Job Descriptions
    Training Modules
    Training Matrix
    Training Records

1.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to confirm
    *Familiarity and compliance with operating procedures
    * Awareness of hazards, causes and control measures associated with LPG
    * Awareness of Safety Report and SMS

SAFE WORK PROCEDURE

  • Review of Safe Work Permit and associated systems to confirm:
    * Procedures are consistent with site activities
    Correct revision is available to personnel

  • Review Work Pack to ensure supporting technical information such as drawings, are aligned to the activities

1.4 Change Management

  • Sample Safe Work procedure to confirm
    * Procedures updates to reflect changes to design or operation
    * Correct document revisions
    *Document reviews conducted in accordance with company policy

1.5 Competency and Training

  • Spot check for compliance with company requirements regarding PPE, working at heights, confined space etc.

Critical Control Protocol 02: EMERGENCY MANAGEMENT

  • Was this element covered during this audit

2.1 Technical Information

  • Review ERP to ensure documents current & personnel contacts list are correct

  • Review ERP to ensure emergency plans align to Major Incident scenarios

  • Review of emergency scenarios to confirm safety and suitability of access routes and muster points

  • Communication systems, internal and external are documented

2.2 Incident and Test Records

  • Review communication systems, internal and external are documented. Sample review of findings from muster and emergency drills to demonstrate compliance to the plan

  • Sample review of records to confirm site alarms (audibility and visual) are operational throughout the plant

2.3 Condition Inspections

  • Survey of the following to ensure adequacey:
    escape routes
    safety equipment condition and certification checks
    access not compromised by temporary equipment or rubish

2.4 Inspections, Maintenance & Test Activities

  • Compliance to 3-Monthly drills

  • Compliance to 3-Yearly emergency exercises involving emergency services

  • Emergency drills with neighboring facilities (where necessary)

2.5 Change Management

  • Sample MOCs to ensure changes with impact on Emergency Management have been addressed

2.6 Competency & Training

  • Review training & competency status for all persons with key roles for Emergency Management

  • Sample survey of personnel for familiarity with Emergency Management Plan

Critical Control Protocol 03: CONTROL OF IGNITION SOURCES

  • Was this element covered during this audit

Ex CERTIFIED ELECTRICAL EQUIPMENT

3.1 Technical Information

  • Ex equipment register upto date including:

    Equipment uniquely identified and registered
    Register current and correct with new tag capture

  • Electrical equipment dossier present

  • Hazardous area drawings availability and current

3.2 Test Records

  • Sample survey of Ex equipment inspection records to confirm appropriate information is captured such as:

    Hazardous zone rating of equipment;
    Ex certificate number
    Compliance with Ex rating, T rating and IP rating, and
    Equipment in good condition (external visual inspection)

3.3 Condition Inspections

  • 2 Yearly sample visual inspections of EEHA

3.4 Inspection & Maintenance

  • Annual Terminal Inspection

3.5 Change Management

  • For new EEHA, sample review to confirm:

    Ex equipment register to confirm uniquely identified and registered.
    Vendor documentation and Hazardous Area drawings confirm suitable Ex rating.

  • Sample Review to ensure MoC procedure adequately followed and any actions closed out

3.6 Competency and Training

  • Sample review of Ex inspector and maintainer competences: confirm training is current and limits of competency clearly defined

EARTHING AND BONDING

3.7 Technical Information

  • Earthing specification

3.8 Test Records

  • Sample review of earthing inspections, maintenance and testing

3.9 Condition Inspections

  • Sample survey of electrical equipment at the facility to confirm that;

    Earthing and bonding installed is appropriate and in good condition
    connections installed correctly and identified

3.10 Inspection & Maintenance

  • Scheduled earthing inspections, maintenance and testing

3.11 Change Management

  • For new electrical equipment sample review to confirm:

    Earthing straps, bar and connections correctly identified and recorded in earthing registered.
    Vendor supplied earthing details

  • Sample Review to ensure MoC procedure adequately followed and any actions closed out

3.12 Competency and Training

  • Sample review of Ex inspector and maintainer competences: confirm training is current and limits of competency clearly defined

Critical Control Protocol 04: PRESSURE RELIEF DEVICES

  • Was this element covered during this audit

4.1 Technical Information

  • PSV Testing protocol/process
    PSVspecification, make, model , service etc is documented

4.2 Test Records

  • Sample review of PSV visual inspection records to ensure that:

    PSVs installed as per PSV Register and facility P&IDs
    PSVs in good condition
    Test certificates and name plates indicate correct set pressure

4.3 Condition Inspection

  • Sample visual inspection to confirm (for example):

    PSVs suitably sited above protected system/vessel
    PSV discharge lines free draining, no liquid hold up, in good condition
    PSV Unobstructed

4.4 Inspection, Maintenance and Witness Testing

  • 10 Yearly PSV function test/replacement (as required)
    Terminal Site inspections (monthly & Annual) inspections of PSVs

4.5 Change Management

  • For new or altered PSVs;

    Sample review of installation and commissioning to ensure correct installation, testing, piping to PSV stress free, approved locking system, blinds removed, valve piping class consistent with P&IDs

4.6 Competency and Training

  • Sample review of records to ensure removal, refurbishment, and testing of PSVs preformed by competent persons in accordance with SOPs

Critical Control Protocol 05:PROCEDURES AND TRAINING OF BULK LPG TANKER DRIVERS

  • Was this element covered during this audit

COMPETENCY & TRAINING

5.1 Technical Information

  • Sample Operations Training & Competency records to confirm training in Tanker Driver procedures including:
    Job descriptions
    Training modules (related to competences)
    Training needs analysis / training requirements
    Training records

5.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to establish:

    Familiarity and competency with operating procedures
    Knowledge & understanding of Major Accidents, hazards, causes and critical controls

PROCEDURES AND TRAINING OF BULK LPG TANKER DRIVERS

5.3 Technical Information

  • Sample review of Tanker Driver procedures to confirm:

    Procedures are consistent with the operational activities
    Correct revision procedures are readily available to appropriate personnel and in the correct format
    Operating proceeds are identified and referenced

5.4 Change Management

  • Sample review of operating procedures to confirm:

    Procedures updated to reflect changes to design or operation
    Corect document revisions
    Document review completed in accordance with SOPs

5.5 Competency and Training

  • Spot checks for compliance with Site SOPs such as PPE

Critical Control Protocol 06:TRAINING OF TERMINAL OPERATORS

  • Was this element covered during this audit

COMPETENCY & TRAINING

6.1 Technical Information

  • Sample Operations Training & Competency records to confirm compliance with appropriate procedure, including:
    Job Descriptions
    Training modules (related to competences)
    Training needs analysis / training requirements
    Training records

6.2 Competency & Training

  • Spot checks of personnel for compliance with training requirements

  • Spot checks of personnel to establish:
    Familiarity and compliance with SOPs
    Awareness of hazards, causes and controls

OPERATING & MAINTENANCE PROCEDURES

6.3 Technical Information

  • Review of Operating Procedures to confirm:
    Procedures are consistent with site operational activities
    Correct revision procedures are readily available to appropriate personnel
    Operating procedures are identified and referenced

6.4 Change Management

  • Sample review of Operating procedures to confirm:
    Procedures updated to reflect changes to design or operation
    Correct document revisions
    Document reviews completed in accordance with company procedures

6.5 Competency & Training

  • Spot checks for compliance to company requirements

Critical Control Protocol 07: EMERGENCY SHUTDOWN

  • Was this element covered during this audit

7.1 Technical Information

  • Instrument specification, make, model, service and functionality is full documented.
    ESD functional specification
    ESD Logic diagram/description
    Instrument testing procedure is defined

7.2 Test Records

  • Review of ESD test records to confirm functionality.

    Shutdown valve (SDV) operation as per ESD Philosophy
    Satisfactory SDV closure time

  • Review of SDV operation test records to demonstrate safe operation

    Suitable fire protection (eg fire safe, PFP, materials of construction)
    Fail safe operation

7.3 Condition Inspection

  • Instruments in good condition (external inspection)
    instrument installed as per Facility P&IDs

7.4 Inspection, Maintenance and Test Activities

  • Terminal inspection (monthly & Annual) for ESD testing
    Sample review of field device calibration records and verify correct settings have been used

7.5 Change Management

  • Review of ESD valve and system repair or replacement records to confirm no change to system performance or integrity
    Sample review to ensure MoC procedure adequately followed and any actions closed out

7.6 Competency and Training

  • Sample review of records to ensure inspection and calibrations are performed by competent persons in accordance with SOPs

Critical Control Protocol 08: CYLINDER FILLING AND INSPECTION PROCEDURES & TRAINING

  • Was this element covered during this audit

COMPETENCY & TRAINING

8.1 Technical Information

  • Sample Operations Training & Competency records to confirm training in Tanker Driver procedures

    Job Descriptions
    Training Modules (related to competences)
    Training needs analysis/training requirements
    Training records

8.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to establish:

    Familiarity and competency with operating procedures
    Knowledge & understanding of Major Accidents, hazards, causes and critical controls

CYLINDER FILLING AND INSPECTION PROCEDURES & TRAINING

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to establish:

    Familiarity and competency with operating procedures
    Knowledge & understanding of Major Accidents, hazards, causes and critical controls

8.3 Technical Information

  • Sample review of Tanker Driver procedures to confirm:

    Procedures are consistent with the operational activities
    Correct revision procedures are readily available to appropriate personnel and in the correct format
    Operating proceeds are identified and referenced

8.4 Change Management

  • Sample review of SOPs to confirm:
    Procedures updated to reflect changes to design or operation
    Correct document revisions
    Document reviews completed in accordance to company policy

8.5 Competency and Training

  • Spot checks for compliance to company requirements

Critical Control Protocol 09: DESIGN OF EQUIPMENT

  • Was this element covered during this audit

9.1 Technical Information

  • Equipment design specification (vessels, piping etc.)

  • Sample review of Maintenance Management System database reports to confirm:

    Status of scheduled tests/inspections is correctly recorded
    Deferred maintenance suitably logged and authorized

9.2 Test Records

  • Sample review of internal inspection records (such as NDT and modification repair of vessels and associated pipe work)

  • Sample review of storage tank/vessels inspection records

    Visual observation to confirm good condition including coatings, welded joints, support and structures
    Verify appropriate protection devices (relief valves, level measurements) installed as per P&ID
    Confirm corrosion protection remains effective

9.3 Condition Inspection

  • Inspection of Vessels for signs of damage, wear or corrosion
    Inspection of pipe work for signs of impact damage, corrosion or wear
    Inspection of hoses for signs of damage or wear

9.4 Inspection, Maintenance and Test Activities

  • Terminal inspections (monthly and annual)
    10 yearly internal inspections
    2 Yearly external visual condition inspection to confirm good general condition of tanks, vessels, structures, coatings and corrosion protection equipment

9.5 Change Management

  • Sample review of engineering modification:

    Tanks/vessels and associated equipment uniquely identified and registered
    Design and operating conditions documented
    Commissioned, inspected and tested in accordance with specification
    Compliance with material specifications, design cos and standards

  • Sample review to ensure MoC procedure adequately followed and any actions closed out

9.6 Competency and Training

  • Sample review and verification of pressure vessel inspector training and qualifications

Critical Control Protocol 10: FIXED FIRE FIGHTING SYSTEMS

  • Was this element covered during this audit

10.1 Technical Information

  • Fire system design basis is fully described together with design basis, flow rates etc.

10.2 Test Records

  • Sample review of firewater system inspection and test records to confirm (for example):

    Sufficient coverage
    sufficient delivery pressure and flow rates (no dry spots)
    Sufficient spouse time

10.3 Condition Inspection

  • Inspection of hydrants for signs of damage, wear, or corrosion.
    Inspection of Deluge for signs of impact, damage, corrosion or wear.
    Inspection of hoses for signs of damage or wear

10.4 Inspection, Maintenance and Test Activities

  • 2-Yearly Firewater flow test.
    3-Yearly LPG Facility emergency fire fighting drill.

10.5 Change Management

  • Sample review of engineering modifications to investigate impact on fixed fire fighting system capabilities.
    Sample review to ensure MoC procedure adequately followed and any actions closed out

10.6 Competency and Training

  • Sample review of fire fighting training and competences, and provision of trained personnel on site.
    Spot check of LPG Facility personnel awareness of fire risks and if fighting controls.

Critical Control Protocol 11: TRAFFIC MANAGEMENT

  • Was this element covered during this audit

COMPETENCY AND TRAINING

11.1 Technical Information

  • Sample Operations Training & Competency records to confirm training in Safe Work Procedure, including:
    Job Descriptions
    Training Modules
    Training Matrix
    Training Records

11.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to confirm
    *Familiarity and compliance with operating procedures
    * Awarness of hazards, causes and control measures associated with LPG
    * Awareness of Safety Report and SMS

TRAFFIC MANAGEMENT PLAN

11.3 Technical Information

  • Review the Traffic Management Plan to confirm:
    Document is consistent with operational activities.
    Correct revision procedures are readily available to appropriate personnel and in the correct format.
    Operating procedures are identified and referenced.

11.4 Change Management

  • Sample changes to Traffic Management Plan to ensure:
    Procedus updated to reflect changes to design or operation.
    Correct document revisions.
    Document reviews completed in accordance with SOPs.

11.5 Competency and Training

  • Spot checks for compliance with SOPs eg PPE

Critical Control Protocol 12: INSPECTION AND MONITORING

  • Was this element covered during this audit

COMPETENCY AND TRAINING

12.1 Technical Information

  • Sample Operations Training & Competency records to confirm training in Safe Work Procedure, including:
    Job Descriptions
    Training Modules
    Training Matrix
    Training Records

12.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to confirm
    *Familiarity and compliance with operating procedures
    * Awarness of hazards, causes and control measures associated with LPG
    * Awareness of Safety Report and SMS

INSPECTION AND MONITORING

12.3 Technical Information

  • Sample review of Inspection & Monitoring program to confirm:
    Checklists are consistent with operational activities.
    Correct revision Procedures are readily available to appropriate personnel and in the correct format.
    Checklists are identified and referenced.
    Inspection & Monitoring program has been developed and implemented

12.4 Change Management

  • Sample review of operating procedures to confirm:
    Procedures updated to reflect changes to design or operation.
    Correct document revisions.
    Document reviews completed in accordance with SOPs.

12.5 Competency and Training

  • Spot checks for compliance with SOPs eg PPE

Critical Control Protocol 13: TRAINING MAINTENANCE PERSONEL

  • Was this element covered during this audit

COMPETENCY AND TRAINING

  • Sample Operations Training & Competency records to confirm training in Safe Work Procedure, including:
    Job Descriptions
    Training Modules
    Training Matrix
    Training Records

13.1 Technical Information

  • Sample Maintenance Personnel Training & Competency records to confirm training in Safe Work Procedure, including:
    Job Descriptions
    Training Modules
    Training Matrix
    Training Records

13.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to confirm
    *Familiarity and compliance with operating procedures
    * Awarness of hazards, causes and control measures associated with LPG
    * Awareness of Safety Report and SMS

OPERATING AND MAINTENANCE PROCEDURES

13.3 Technical Information

  • Sample review of Maintenance Operating procedures to confirm:
    Procedures are consistent with operation activities
    Correct revision Procedures are readily available to appropriate personnel and in the correct format.
    Checklists are identified and referenced.

13.4 Change Management

  • Sample review of operating procedures to confirm:
    Procedures updated to reflect changes to design or operation.
    Correct document revisions.
    Document reviews completed in accordance with SOPs.

13.5 Competency and Training

  • Spot checks for compliance with SOPs eg PPE

Critical Control Protocol 14: PROCEDURES AND TRAINING OF BULK LNG TANKER DRIVERS

  • Was this element covered during this audit

COMPETENCY & TRAINING

14.1 Technical Information

  • Sample Operations Training & Competency records to confirm training in Tanker Driver procedures

    Job Descriptions
    Training Modules (related to competences)
    Training needs analysis/training requirements
    Training records

14.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to establish:

    Familiarity and competency with operating procedures
    Knowledge & understanding of Major Accidents, hazards, causes and critical controls

PROCEDURES AND TRAINING OF BULK LNG TANKER DRIVERS

14.3 Technical Information

  • Sample review of Tanker Driver procedures to confirm:

    Procedures are consistent with the operational activities
    Correct revision procedures are readily available to appropriate personnel and in the correct format
    Operating proceeds are identified and referenced

14.4 Change Management

  • Sample review of operating procedures to confirm:

    Procedures updated to reflect changes to design or operation
    Corect document revisions
    Document review completed in accordance with SOPs

14.5 Competency and Training

  • Spot checks for compliance with Site SOPs such as PPE

Critical Control Protocol 15: PROCESS SHUTDOWN SYSTEM

  • Was this element covered during this audit

15.1 Technical Information

  • Instrument specification, make, model, service and functionality is fully described.
    Instrument testing procedure is defined.

15.2 Test Records

  • Sample review of instruments to ensure(:

    Instruments installed as per P&ID.
    Instruments in good condition (external inspection).

15.3 Condition Inspections

  • Process Shutdown Systems are regularly tested.

15.4 Inspection and Maintenance

  • Sample review of field devices calibration records and verify correct settings have been used.

15.5 Change Management

  • Sample review to ensure MoC procedure adequately followed and any actions closed out

15.6 Competency and Training

  • Sample review of records to ensure inspection and calibrations are preformed by competent person in accordance to SOPs

Critical Control Protocol 16: DOCUMENTATION SYSTEMS

  • Was this element covered during this audit

COMPETENCY & TRAINING

16.1 Technical Information

  • Sample applicable personnel Training & Competency records to confirm training in Tanker Driver procedures

    Job Descriptions
    Training Modules (related to competences)
    Training needs analysis/training requirements
    Training records

16.2 Competency and Training

  • Spot checks of personnel for compliance with training requirements
    Spot checks of personnel to establish:

    Familiarity and competency with Documentation Systems
    Knowledge & understanding of Major Accidents, hazards, causes and critical controls.
    Awareness of the Safety Report and the Safety Management System

DOCUMENTATION SYSTEMS

16.3 Technical Information

  • Sample review of Documentation System to confirm:

    Documentation Systems are consistent with the operational activities
    Correct revision procedures are readily available to appropriate personnel and in the correct format
    Operating proceeds are identified and referenced

16.4 Change Management

  • Sample review of Documentation System to confirm:

    Documentation Systems have been updated to reflect changes to design or operation
    Corect document revisions
    Document review completed in accordance with SOPs

16.5 Competency and Training

  • Spot checks for compliance with Site SOPs such as PPE

General audit findings

17 Any other audit findings

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