Auditing
Process safety and security management program audits are a useful tool to improve performance when done by experienced and knowledgeable leaders. An experienced auditor, or audit team, will use a systematic and structured approach to evaluating and improving management systems. Through these audits, organizations can identify, assess, and mitigate risks. They ensure compliance with safety and security standards, and continually improve safety performance and security while reducing the likelihood of accidents and incidents in their facilities.
All of AcuTech’s audits evaluate process safety, security, and crisis & emergency management programs from two perspectives:
The management systems review of design and effectiveness:
- Commitment, diligence, and comprehensiveness
- Appropriateness to the level of hazards/vulnerabilities of the process
- Employee involvement and knowledge
- Methods employed compared to state-of-the-art practice in similar industries
- Completeness and quality of documentation
The technical approaches employed including:
- Methods employed compared to state-of-the-art practice in similar industries
- Physical systems in place
- Appropriateness to the level of hazards/vulnerabilities of the process
- The completeness and quality of documentation
- Implementation of the element
Process Safety Audits
AcuTech has been a leading force in Process Safety Management (PSM) consulting and training since 1994, partnering with organizations to enhance process safety programs through audits, gap analyses, and best practice benchmarking. Our seasoned consultants have collectively conducted thousands of PSM audits, providing comprehensive support from planning and onsite execution to reporting. Whether leading or participating in audit teams, AcuTech’s experts adhere to audit protocols developed using guidance from OSHA, the EPA, and other relevant regulatory bodies. AcuTech consultants understand the questions to ask and how to interpret findings to the benefit of our partners.
When needed, AcuTech has the capability to add significant value to these protocols and develop and maintain “Continuous System Improvement” (CSI) criteria. For instance, a broader list of PSM audit criteria that can be used if an organization wishes to evaluate their PSM program on a deeper basis. This will allow recommendations beyond the basic compliance requirements. Additionally, AcuTech offers training in PSM audit planning, execution, and reporting as part of our comprehensive suite of PSM-related training services.
AcuTech also offers auditing services aligned with international and national standards in key risk management areas, providing a foundational framework for responsible companies. Our comprehensive approach encompasses consulting, training, and support in formal management system development and implementation. It includes self-verification of compliance, and certification pursuits, ensuring alignment with these standards to enhance organizational resilience.
Security Audits
AcuTech specializes in integrating security management systems to counter both external and internal threats across various domains. We conduct audits to evaluate the effectiveness and compliance of facility site security plans, assisting companies in sustaining robust security measures while addressing vulnerabilities identified through security risk assessments. From formal management system development to certification pursuits, we ensure alignment with international and national standards. Our comprehensive approach includes providing auditing services alongside consulting, training, and support.
Our seasoned consultants bring expertise in Operational Technology/Industrial Control Systems (OT/ICS) cybersecurity, with a focus on conducting thorough audits. In addition to strategic security planning and cost/benefit analyses, AcuTech tailors security measures to suit each client’s unique needs.
Moreover, AcuTech’s security auditing services encompass a thorough understanding of the CFATS cycle, ensuring clients receive critical support in managing security vulnerabilities and compliance. Leveraging our expertise, we aid in drafting comprehensive site security plans in compliance with the stringent mandates of the Maritime Transportation Security Act (MTSA), enhancing port and waterway safety.
Crisis & Emergency Management Audits
AcuTech offers specialized auditing services in crisis and emergency management systems, aiming to bolster organizational preparedness and response capabilities during unforeseen disasters or incidents. Our comprehensive approach includes conducting audits aligned with standards such as NFPA 1600 and ISO 22301. AcuTech ensures compliance and effectiveness in emergency management and business continuity programs.
With expertise in various management systems, AcuTech provides comprehensive support in auditing, reviewing, and certifying crisis and emergency management systems. Our services encompass business continuity management system development, business impact analysis, BCM planning, trainings, and compliance verification, aligning organizations with internationally recognized standards.
- PSM/RMP audits
- Process safety culture assessments
- Targeted gap analysis of PSM program elements
- Development of advanced audit protocols for continuous improvement
- Occupational health and safety audits
- Physical security audits
- Evaluate the effectiveness and compliance of facility site security plans
- Security management system audits
- CFATs and MTSA support
- Cyber security audits
- IT/OT audits
- Crisis and emergency management program audits
- Training
AcuTech’s consultants are well versed in codes and standards and will refer to these as well as each client’s local jurisdiction codes and standards. A sampling of the relevant codes and standards can be found below.
- Process Safety Management (PSM) Standard (29 CFR 1910.119) – OSHA requirements for managing highly hazardous chemicals, including PHA, training, and mechanical integrity.
- Risk Management Program (RMP) Rule (40 CFR Part 68) – EPA requirements for preventing and mitigating chemical accidents at facilities using listed hazardous substances.
- SEVESO Directive – European Union directive establishing major accident prevention and emergency planning requirements for facilities handling dangerous substances.
- COMAH Regulations – UK regulations implementing SEVESO principles, focused on preventing major accidents and limiting their consequences.
- CalARP – California’s accidental release prevention rule, aligned with and expanding upon the federal RMP program.
- CalOSHA PSM – California’s PSM regulation with stricter requirements than federal OSHA PSM, including hierarchy of controls and prevention program enhancements.
- NJ TCPA – New Jersey Toxic Catastrophe Prevention Act regulating facilities with extraordinarily hazardous substances through prevention and emergency response programs.
- DE EHA – Delaware Extremely Hazardous Substances Accidental Release Prevention Program, requiring risk management and prevention practices for listed chemicals.
- SAWS – Singapore’s Safety Case regime under the Workplace Safety and Health (Major Hazard Installations) Regulations, requiring safety case development and continuous risk management.
- IEC 61511 – International standard for functional safety and safety instrumented systems in the process industries.
- API Standards – Industry standards covering inspection and safety, including API 510 (pressure vessels), API 570 (piping), and API 653 (aboveground storage tanks).
- ISO 45001 – International standard for occupational health and safety management systems, providing a framework for managing safety risks.
- NFPA Standards – Fire and explosion prevention standards such as NFPA 654 for combustible dust hazards.
- ASME Codes – Engineering codes for design, construction, inspection, testing, including ASME B31.3 for process piping and the ASME Boiler and Pressure Vessel Code.
- EPSC RBI Guidelines – European guidance for implementing risk-based inspection programs to prioritize inspection activities based on risk.
Our consultants have contributed to the following standards, codes, and programs:
- AcuTech was the contractor selected to write the revision of the Center for Chemical Process Safety’s (CCPS) Guidelines for Auditing Process Safety Management Systems, which follows the CCPS Guidelines for Risk Based Process Safety. This guideline contains guidance for auditing voluntary consensus programs in process safety, such as Safety and Environmental Management Programs (SEMP), the ACC’s RCMS program, RC-14001, and others.
- Author of CCPS Guidelines for Essential Practices for Creating, Strengthening & Sustaining Process Safety Culture
- NFPA 652 Management System Audit Protocol