Five Star Process

Safety Audit
Specification October 2017

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 Contents Page
1 Introduction to the Five Star Process Safety Audit model 1
2 Five Star Audit process 2
3 Scoring and grading system 3
4 Audit report and action planning 4
5 Preparing for the audit 5
6 Standardisation and quality assurance 5
7 Specification details 6
8 Specification guidance 8

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 D
1. Introduction to the
Five Star Process Safety
Audit model
This document is intended to provide a summary of the
British Safety Council Five Star Process Safety Audit,
together with details of the audit specification.
The Five Star process safety Audit process involves an in-depth examination of
an organisation’s entire process safety management system(s) and associated
arrangements.

Process safety management is the way an organisation manages and mitigates the
risk of a catastrophic incident. Such incidents have the potential to harm, injure or
kill large numbers of people, including members of the public, cause significant
damage to business assets, the environment and to business reputation.

The audit examines the whole of an integrated occupational management system with
a particular focus on the key aspects of managing process safety in the workplace and
offers a structured path for continual improvement towards best practice status.

Utilising extensive worldwide industry experience and acknowledging aspects of

internationally recognised occupational health and safety management systems
and relevant standards, the British Safety Council has developed a unique Five
Star Audit model that objectively evaluates process safety management systems
and arrangements against current best practice techniques. The audit model is
reflective of the recognised PLAN – DO – CHECK – ACT management cycle.

Five Star Process Safety Audit: 2017 specification

Pl
an

Organisational
commitment and
structure

Senior (top)
Act

Management
Strategic

review and
Five Best planning
continual
improvement
Practice
Indicators

Performance Implementation
evaluation and operation

Ch
e ck
Do

Five Best Practice Indicators:

• Leadership and Commitment • Organisational health
• Stakeholder participation and safety culture
• Risk management • Continual improvement

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 1
 2. Five Star Audit process

The Five Star Process Safety Audit is carried out using the
following process of objective verification:
The auditor will review all aspects of the organisation’s occupational health
and process safety management systems and associated arrangements against
the requirements of the British Safety Council’s Five Star process safety audit
specification. The auditor will also assess the effectiveness of implementation
of these arrangements through an inspection of relevant (agreed) site(s) and
sampling of operational activities.

During the audit process, management, staff and other stakeholders will
be interviewed (as agreed) to confidentially discuss aspects of occupational
health and safety and catastrophic risk management relevant to their roles
and responsibilities.

A subsequent report is produced identifying the strengths and areas for

improvement within the organisation’s process safety management systems.
The report also includes observations and recommendations, together with
action planning, for consideration.

Five Star Process Safety Audit 2017: Delivery Process

Review of Occupational health and process

safety management documentation

Interview with management,

staff and other stakeholders

Site tour, inspection and

operational sampling

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 2
3. Scoring and
grading system

The Five Star Process Safety Audit outcome is determined

by application of the British Safety Council’s quantified
system of evaluation (see below).
The overall audit grading is as follows:

Marks % Star rating

92 – 100: Excellent
(best practice verified in most elements)

85 – 91.9: Very good

(best practice verified in many elements)

75 – 84.9: Good
(best practice verified in some elements)

60 – 74.9: Adequate
(significant improvements required
to achieve best practice)

50 – 59.9: Less than adequate

(extensive improvements required
to achieve best practice)

The Five Star Process Safety Audit process focuses on five sections (65 elements)
and five best practice indicators (BPI) as shown below:

Section Audit criteria Maximum accredited audit figure

1. Organisational commitment 750 points
and structure
2. Strategic planning 1,125 points
3. Implementation and operation 1,500 points
4. Performance evaluation 1,125 points
5. Senior (top) Management review 500 points
and continual improvement
Total: 5,000 points

BPI 1: Leadership
BPI 2: Stakeholder participation
BPI 3: Risk management
BPI 4: Organisational health and safety culture
BPI 5: Continual improvement

The five sections of the audit are divided into 65 elements which attract a maximum
numerical value of 5,000 points. Several of these elements are considered as essential
components within a best practice process safety management system, reflected by
their inclusion within more than one section of the audit model. Wherever an element
of the audit is not applicable to the organisation, it is excluded from the audit.

Individual element findings and outcomes are detailed within the subsequent
audit report.

Throughout the audit, five best practice indicators are evaluated either as
elements in their own right, or alternatively as scoring areas within other
elements. The overall scoring for each of these indicators is illustrated separately
within the report’s executive summary against an indicative level of best
practice. This aspect of the audit process is designed to encourage organisations
to focus upon continually developing their process safety management systems
and organisational safety culture.

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 3
4. Audit report and
action planning

Upon completion of the audit process, a comprehensive

report is prepared by the auditor and will be issued within
twenty eight (28) days. The report content will include:
• Executive summary (including graphical performance indicators)
• Overall star grading and sectional scoring
• Observations
• Recommendations for improvement
• Action planning tables.
The recommendations against the requirements of the Five Star process safety audit
specification are presented in tabulated colour coded format as per the key below:

Colour code Priority Definition

High: Recommendations to be implemented
Less than 60% awarded as a High priority action
in this element
Medium: Recommendations to be implemented
Between 60% and 100% as a Medium priority action
awarded in this element
Low: Monitor existing arrangements in
100% awarded in this this area to demonstrate continual
element improvement
Not applicable The requirements of this element
are not applicable

The green coded area indicates full marks have been awarded in respect
of the Five Star scoring criteria. The organisation should continue to monitor
these elements in order to maintain best practice.

The amber coded area indicates were some marks have been deducted.

The red coded area indicates were significant marks have been deducted in
respect of the Five Star scoring criteria.

Wherever marks have been deducted, a recommendation will be provided that,

if followed and effectively implemented, will assist the organisation in working
toward best practice standards.

The action planning tables are also designed to allow the organisation to plan
for implementation of the recommendations by self populating the relevant
columns as appropriate.

If any elements of the audit specification are considered as not applicable to

the audited organisation, then these will be left blank within the relevant table
and indicated as N/A.

As with any time-bound audit, observations and recommendations made are

based upon the agreed scope and depth of information made available during
the audit process.

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 4
5. Preparing
for the audit

In order for the audit process to be as effective as possible,

it is considered important that pre-audit preparations are
agreed and completed.
Once all logistical arrangements have been confirmed with the relevant British
Safety Council account manager, the allocated auditor will make contact with
the appropriate person within the organisation no later than ten (10) days before
the audit start date to discuss and agree the audit details (timings, interviews,
site inspections, induction process, security / PPE arrangements, etc)

This specification document (see section 8) outlines the various forms

of information and documentation that the auditor is likely to request for
review, together with personnel who may be requested for interview.

It would be advantageous if documentation is readily available (either

electronically or in hard copy) for the auditor. Some of this material may
be retained by the auditor during the audit process (with explicit consent
of the auditee).

All British Safety Council auditors are mindful of operational demands and
requirements and will apply as much flexibility with the audit schedule as is
reasonably practicable to accommodate such matters.

6. Standardisation and
quality assurance

British Safety Council auditors are appropriately qualified, highly

experienced health and safety professionals who are subject
to a robust internal quality assurance and appraisal process,
in addition to the requirements of relevant professional bodies
with whom they are members.
All audit reports are technically verified and quality endorsed before being
issued to clients. Auditors are also subject to “on-site” monitoring (subject
to client agreement) on a sampling basis.

Mandatory auditor standardisation meetings also take place on a regular basis.

This specification document is reviewed at least annually to reflect changes

in legislation and relevant developments and trends in occupational health
and safety and process safety management best practice technique.

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 5
7. Specification details

Element headings
Plan Do Check Act

Section 1 Section 2 Section 3 Section 4 Section 5

Organisational Commitment Strategic planning Implementation Performance evaluation Senior (top) Management
and structure (1,125 points) and operation (1,125 points) review and continual
(750 points) (1,500 points) improvement
(500 points)
1.01 S
 cope, nature and scale 2.01 Status assessment 3.01 Implementation of 4.01 Monitoring of 5.01 Senior (top)
of occupational health (including risk assessment and occupational health management review
and safety management benchmarking) operational health and and safety objectives process (includes
system safety controls and process safety process / OH&S
strategy objective setting and
programmes)
1.02 O
 ccupational health 2.02 Process safety 3.02 Safe operating 4.02 Monitoring and 5.02 R
 eview of effectiveness
and safety, MAPP strategy, Occupational procedures (safe analysis of asset of leadership,
or equivalent policy health and safety systems of work) management resources and support
statement objectives and
planning
1.03 S
 tructure (roles, 2.03 Provision of resource 3.03 Permit (and Proactive measurement 5.03 Continual improvement
responsibilities, and support authorisation) to work (evaluation and
accountabilities and systems 4.03 Auditing and planning)
authorities) Inspection (internal and
external)
1.04 C
 ompetence and 2.04 Strategic leadership 3.04 Management and 4.04 Risk assessment 5.04 Corporate social
capabilities and corporate control of work review responsibility
governance (planning) equipment
1.05 L
 eadership and 2.05 Stakeholder 3.05 Manual handling 4.05 Evaluation of legislative
corporate governance engagement, (and other) compliance
participation and
assurance (planning)
1.06 S
 takeholder 2.06 Identification 3.06 Management and 4.06 Health surveillance
engagement, of hazards and control of workstation monitoring
participation and improvement ergonomics (including
assurance opportunities DSE)
1.07 Information and 2.07 Risk Assessment and 3.07 Workplace 4.07 Monitoring of
communication operational control management contractors, suppliers
management (housekeeping, and outsourced
welfare, storage function(s)
facilities, etc)
1.08 Organisational 2.08 Plant and process 3.08 Management of 4.08 Evaluation of
commitment toward design occupational road effectiveness of
health and wellbeing risk (including information and
traffic and transport communication
management) management
1.09 Change management 2.09 Designation of 3.09 Safe Isolation Reactive measurement
operational priorities
4.09 Accident, process
safety incident,
near miss report
and investigation
monitoring
1.10 L
 egislative (and other) 2.10 C
 hange management 3.10 Working at height 4.10 Ill health and
compliance (planning) absenteeism
monitoring
2.11 Competence 3.11 Lifting operations 4.11 Loss/damage analysis
management system
2.12 Emergency 3.12 Management of
arrangements (planning) Inventory of dangerous
substances

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 6
7. Specification details cont.

Element headings
Plan Do Check Act

Section 1 Section 2 Section 3 Section 4 Section 5

Organisational Commitment Strategic planning
and structure (1,125 points)
(750 points)
2.13 Management and
control of contractors
(planning)
2.14 A
 sset management and
procurement (planning)
2.15 Occupational health
and wellbeing
(planning)
2.16 Planning for a positive
health and safety
culture
Implementation Performance evaluation Senior (top) Management
and operation (1,125 points) review and continual
(1,500 points) improvement
(500 points)
3.13 Pressure systems
3.14 Control of hazardous
substances (including
biological agents)
3.15 Management and
control of asbestos
3.16 Management and
control of electrical
hazards
3.17 Management and
control of noise
3.18 Management and
control of vibration
hazards
3.19 Personal protective
equipment
3.20 Competence
management systems
(implementation)
3.21 Management of
psychosocial hazards
3.22 Implementing a
positive health and
safety culture
3.23 E
 mergency
arrangements
(implementation) and
controls
3.24 Fire safety
management
(protective and
preventive controls)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 7
8. Specification guidance

Five Star Process safety Audit 2017 : Specification details. (Please note: This table contains typical information
likely to be reviewed during the audit process, but is not a definitive index).
Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Organisational Explicit commitment Policy statement Policy statement Review of training Evidence that senior
Commitment and within the OH&S, consistent with readily available to, records (top) management carry
process safety MAPP policy subsequent OH&S and understood by, all out a formal review of
Interviews with senior
management system statement to: objectives and planning levels of management, OHSMS performance
management
staff and other
Prevention of Description of how Evidence of policy
stakeholders (verified Accident/incident/near
major accidents OHSMS elements statement reviewed
through interview) miss/non-conformance
and catastrophic interlink with each other
analysis Evidence of strategy
incidents, mitigation and how process safety Senior managers
planning reflective of
of the consequences. is integrated with SMS. visible and engaged in Corporate and other
top management review
risk management management reports
Legislative (and Evidence of OHSMS and outcomes
other) compliance; planning aligned with Training and induction Minutes from
Evidence of learning
continual overall business strategy records management and other
from others in the
improvement; and processes relevant meetings
Effective sector and sharing
periodic review;
Evidence of OHSMS implementation of Inspection and audit information and
prevention of
status assessment OHSMS through reports intelligence.
injury and ill
observation and
health; provision of Evidence of internal Evidence of risk Interview with top
interviews
adequate resources; and/or external assessment review management
management of risk; OHSMS performance Effective
consultation with OH&S objectives and Corporate health and
benchmarking implementation of
stakeholders programme monitoring safety reporting
risk assessment and
OHSMS programme/plan
controls (sampling) Evaluation of Primary related
Policy readily
available and OHSMS is capable of legislative compliance elements
Primary related
provides the delivering appropriate All elements in this
elements Primary related
framework for risk control and section
(3.01)(3.02) elements
occupational health mitigation.
remainder of (4.01)(4.02)(4.03)
and safety (OH&S) Evidence of strategic applicable section 3 (4.04)(4.05)(4.09)
objective setting and leadership and provision elements (4.10)(4.12)
is consistent with of suitable resources and
corporate values support
Endorsed by top Primary related
management elements
OHSMS is defined (2.01)(2.02)(2.03)(2.04)
and suitably (2.05)(2.09)
scoped including
consideration of
the full context of
the organisation’s
activities

Operational
procedures and
arrangements are
clearly stipulated
within the OHSMS

Stakeholder
awareness of policy
and OHSMS content
(verified through
interview).

Primary related
elements
(1.01)(1.02)(1.05)
(1.10)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 8
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Structure (Roles, Defined roles and Defined roles and Evidence of effective Evaluation of training Regular CPD/appraisal
responsibilities, responsibilities responsibilities within supervision and role records reviews
accountabilities and within OHSMS OHSMS competency
Confirmation Role development plans
authorities)
Defined OH&S and process Training records of awareness,
organisational safety objectives understanding and
CPD programmes
structure (organisational and development of job
individual) roles through interview
and appraisal records
Leadership and Appointed top Appraisal planning Employee Accident/ process Improvement planning
corporate governance level management understanding and safety incident
Role development Records of management
responsible for awareness (verified statistics, ill health,
review
OH&S Responsible actions through interview and non-conformance
allocated within process inspection) monitoring and Corporate reports
Policy and MAPP
safety planning analysis include reporting
statement endorsed Senior managers
on process safety
by top level Demonstrable visible and engaged Review of process
performance
management involvement in status in process safety safety objectives and
assessment process management. plans Primary related
Demonstrable
elements
commitment Demonstrable support Appraisal records Demonstrable
All elements in
(verified through for lines of responsibility evidence of
Suitable levels of this section
interview) at all management
Evidence of stakeholder supervision and
levels involvement (minutes
engagement (minutes of resource
of meetings,
Ownership of meetings, training etc.)
Evidence of effective investigations, site
relevant process
Evidence of managing management of inspections, risk
safety issues by top
change operational risk assessment, etc.)
management
(including psycho- in the evaluation of
Primary related Demonstrable social) relevant performance
elements involvement in indicators
promoting positive Evidence of
(1.01)(1.02)(1.03)
health and safety culture participation in Primary related
(1.05)(1.06)(1.08)
process safety of non- elements
(1.10) Primary related managerial roles All elements in
elements this section
(1.06)(2.01-2.08)(2.11) Primary related
elements
All applicable
elements in this
section

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 9
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning
Commitment and (1,125 points)
structure
(750 points)
Plant and Process Clear design intent Inherent safe design as
Design for inherent safety a central principle of
and fail to safe the plant and systems
shutdown. specification.
Mitigation of Risk assessment drives
consequences of plant design.
a major accident
Structured hazard
an integral part of
identification and
design intent.
risk assessment
ALARP principles methodologies followed
adopted in design eg HAZOPs,
QRA, LOPA studies.
Primary related
elements Intelligent customer when
(1.01)(1.02) contracting in plant,
equipment and support.
Interfaces with people
(operators, maintenance
contractors) and human
factors fully considered
during design.
S3: Implementation S4: Performance S5: Management
and operation evaluation review and
(1,500 points) (1,125 points) improvement
(500 points)
Inherent design and Issues and incidents Improvements logged
mitigation validated related to design, and reviewed.
during commissioning commissioning,
Technological and
operation and
Plant operated and process safety advances
maintenance recorded
maintained to inherent across similar industries
and investigated.
design concept. reviewed.
Data logging and trend
Management of Primary related
analysis
change ensures design elements
integrity maintained Primary related (5.01)(5.03)
elements
Shutdown systems
(4.01)(4.02)(4.04)
tested and validated
(4.04)(4.05)(4.07)
Primary related (4.09)(4.11)
elements
(3.01)(3.02)(3.4)(3.06)
(3.13)(3.23)

Safety integrity levels set

according to inherent risk.

Hazardous area
classification / ATEX
compliance.

Protection against cyber

attack inherent in design.

Safe shutdown and

mitigation integrated
into design.

Primary related
elements
(2.04)(2.06)(2.07)(2.08)
(2.09)(2.12)(2.14)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 10
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Designation Inherent Systems and procedures Plant operated within Excursions outside Performance of the
of Operational commitment to designed to meet safe safe operational designed operating plant, operating
Parameters maintenance of design intent. parameters. parameters, recorded, systems and alarms,
safe operational reported and and shutdown systems
Risk assessment Alarm management
parameters. reviewed.
drives designation of systems optimized. investigated
Primary related operational parameters. Improvements identify
Critical tasks, including Investigation covers
elements to reduce or eliminate
Human factors and plant action in abnormal / underlying causes
(1.01)(1.05)(1.10) challenges to the
and process interfaces emergency situation of people, plant and
integrity of the plant
effectively integrated. clearly identified. processes as an
and equipment
integrated system.
Critical tasks and Staff trained in
Primary related
procedures identified. critical tasks Primary related
elements
elements
Normal and abnormal Primary related (5.01)(5.03)
(4.01)(4.02)(4.04)
operational conditions elements
(4.04)(4.05)(4.07)
clearly specified. (3.01)(3.02)(3.4)(3.06)
(4.09)(4.11)
(3.13)(3.20)(3.23)
Alarms management and
controls designated to
facilitate maintenance
of safe operational
parameters.

Primary related
elements
(2.04)(2.06)(2.07)(2.08)
(2.09)(2.11)(2.12)(2.14)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 11
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Information and Policy/process for Process safety planning Current information Internal/external Top management
communication information control documentation and and documentation inspection and audit review process safety
management and communication information consistent readily available outcomes performanceStakeholder
management with policy requirements involvement in continual
Policy requirements Evidence of effective
improvement
Clear link to quality Training schedules verified document control
management Corporate reports
Process safety Effective Evidence of effective
systems (if
objectives/programmes/ understanding monitoring of change Records of management
referenced)
plans and awareness of management process review
Evidence of effective risk assessment,
Primary related Evidence of effective Primary related
communication of operational controls
elements monitoring of elements
policy statement and and procedures
(2.02)(2.03)(2.04)(2.06) internal and external (5.01)(5.04)
content of OHSMS (verified through
(2.07)(2.09)(2.11) communication
interview and
Primary related
observation) Primary related
elements
elements
(1.01)(1.02)(1.03) Primary related
(4.01)(4.02)(4.08)
(1.04)(1.05)(1.06) elements
(1.07) (3.02)(3.20)(3.21)
(3.22)
Stakeholder Policy/process Evidence of stakeholder Evidence of Evaluation of training Evidence of stakeholder
consultation and for consultation involvement in process stakeholder involvement in
Evidence of completed
participation with stakeholders safety objective setting, involvement in management review
actions arising from
(internal and planning and risk development of risk process
OH&S committee
external) management process, management and
meetings (and other Communication of top
including emergency controls (verified
Policy/process such forums) management review
planning through sampling,
for stakeholder
interview and review) Evidence of completed Corporate reporting
participation in Schedule for OH&S
actions arising from
policy and process committee meetings Risk assessments Internal reporting
performance indicators
safety management
Terms of reference for Training records (inspections, audits, Audit reports
system development
stakeholder forums accident investigations
Evidence of OH&S Primary related
Organisational etc.)
Training schedule committee meetings elements
structure
(and other such Evidence of monitoring (5.01)(5.03)(5.04)
Primary related
Defined roles and forums) of process safety
elements
responsibilities objectives
(2.02)(2.03)(2.04)(2.06) Site induction records
Consultation and (2.07)(2.08)(2.11) Primary related
Permit to work records
participation in elements
change management Primary related All elements in
elements this section
Primary related
All elements in
elements
this section
(1.01)(1.02)(1.03)
(1.05)(1.06)(1.09)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 12
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Competence and Policy/process Training needs analysis Training records Accident/process Top management
capabilities for ensuring safety incident analysis review
Plan/programme for Evidence of trainer
competency and investigation
ensuring competency competency Appraisal records
requirements reports
CPD/appraisal planning Training evaluation Effective continual
Defined roles and Audit findings
improvement process
responsibilities Mentoring/coaching plan Role competency
Risk assessment
records Review of statutory
Organisational Primary related reviews
training requirements
structure elements Effectiveness
Statutory training
(2.02)(2.03)(2.04)(2.05) of operational Primary related
Primary related compliance
(2.06)(2.07)(2.09) controls (verification elements
elements
through interview, CPD maintenance (5.01)(5.02)(5.04)
(1.01)(1.02)(1.04)
observations)
(1.05)(1.06)(1.10) Appraisal records
Risk assessment
Review of training
sampling
records and schedules
Permit to work records
Primary related
Evacuation drill elements
records All elements in
this section
Primary related
elements
All elements in
this section
Occupational health Policy/process for OH plan/schedule Evidence of first aid Accident/ill health/ OH plan review
and wellbeing OH and wellbeing provision (including absenteeism statistics
Lifestyle/wellbeing Review and setting
(including psycho- equipment and
promotion plan/schedule Risk assessment of process safety
social hazards) personnel)
reviews objectives
Health surveillance
Defined roles and Training records
schedules Stakeholder perception Corporate reporting
responsibilities
Health surveillance and awareness
Training plan Primary related
Demonstrable records (interviews)
elements
commitment OH and wellbeing
Evidence of lifestyle First aid records (5.01)(5.02)(5.04)
(verified through objectives
and wellbeing
interview) at all Stakeholder surveys
Primary related promotion
levels
elements Health surveillance
Return to work
Ownership of (2.02)(2.03)(2.05)(2.08) records
interviews
relevant process (2.11)
safety issues by top Primary related
Support mechanisms
management elements
Risk assessments (4.01)(4.02)(4.04)
Primary related (4.06)(4.09)(4.10)
elements Primary related
(1.01)(1.02)(1.04) elements
(1.05)(1.06)(1.08) (3.01)(3.02)(3.05)
(1.10) (3.06)(3.07)(3.12)
(3.13)(3.15)(3.16)(3.19)
(3.20)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 13
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Change management Policy/process for Examples of planning for Effective risk control Effective monitoring of Review of change
management of change (organisational implementation audit outcomes management policy/
change and operational) (observation and process
Inspection records
review)
Defined roles and Design and project plans Continual improvement
Project meeting
responsibilities Training records planning
Evidence of stakeholder minutes
Evidence of consultation in planning OH&S committee Change management
Safety surveys
consultation with for change meeting minutes project review
and participation of Risk assessment
Evidence of risk Risk assessment Top management
stakeholders with reviews
assessment for change (change management review process
change management
management sampling) Effective
process Corporate reporting
understanding and
Primary related Inspection and audit
Primary related awareness of amended Primary related
elements outcomes
elements risk assessment, elements
(2.03)(2.04)(2.05)(2.06)
(1.01)(1.03)(1.04) Primary related operational controls (5.01)(5.03)(5.04)
(2.07)(2.09)(2.10)
(1.06)(1.07)(1.09) elements and procedures
(1.10) (3.01)(3.02)(3.03) (verified through
(3.18)(3.19)(3.20) interview and
(3.21) observation)

Primary related
elements
(4.02)(4.03)(4.04)
(4.05)(4.07)(4.08)
(4.12)
Process safety Reference to process Process safety objectives Awareness of Evidence of monitoring Top management
objectives safety objectives set at organisational, process safety of process safety review of process safety
within policy functional and individual objectives throughout objectives (e.g. audits, objectives
statement levels organisation senior management
Revised planning for
(interview) meeting minutes and
Policy/process for Evidence of stakeholder achievement of process
OH&S committee
setting process participation during Evidence of safety objectives
meeting minutes)
safety objectives setting of objectives consultation and
Corporate reports
involvement of relevant Management reports
Reference to Planning for provision
stakeholders (e.g. Management meeting
objective setting of resources required to Appraisal records
OH&S committee minutes
within stakeholder achieve objectives
meeting minutes, Audit outcomes
involvement process Primary related
OH&S plans reflective appraisal records)
Primary related elements
Primary related of targets
Sampling of elements All elements
elements
Appraisal process progression of process (4.01)(4.02)(4.03) within section
(1.01)(1.02)(1.05)
safety objectives
(1.06) Primary related
elements Risk profiles
(2.02)(2.03)(2.04)(2.05) (organisational and
(2.06)(2.09)(2.11) operational)

Primary related
elements
(3.01)(3.19)(3.20)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 14
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Process safety Commitment to Documented plan Sampling of process Audit outcomes Top management
planning process planning safety plan (inspection review
Link to other operational Minutes from
within policy and interview)
plans management and Continual improvement
statement
Risk assessments OH&S committee
Audit planning Evaluation of
Policy/process for (sampling) meetings (and other
compliance records
process safety Training schedules such forums)
Maintenance records
planning and review External accreditation
Evidence of process Accident ill/health
including periodic Statutory inspections
safety considerations analysis Financial and project
process hazard etc.
reviews within financial planning reviews
Management reports
Effective
Defined roles and Documented budget Management reports
implementation of OH&S objective
responsibilities Project planning OH&S plan/control monitoring Corporate reports
arrangements
Evidence of Business recovery plans Risk assessment Primary related
(inspection and
participation of reviews elements
Evidence of stakeholder interview)
stakeholders All elements
in OHSMS involvement in planning Evaluation of
PTW documentation within section
development compliance records
Primary related Evidence of resource
Primary related elements Audit and inspection
provision
elements (2.01)(2.03)(2.04)(2.05) records
(1.01)(1.02)(1.03) (2.06)(2.07)(2.08)(2.09) Training records
Primary related
(1.05)(1.06) (2.11)
Primary related elements
elements (4.01)(4.02)(4.03)
(3.01)(3.02)(3.19) (4.04)(4.05)(4.06)
(4.12)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 15
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Asset Management, Policy for asset Asset management Asset register kept Asset performance Performance, life
Procurement, register and life strategy upto date routinely monitored expectancy and asset
outsourcing cycle assessment to identify reduced failures reviewed
Designation of critical PIDs reflect design
and contractor integrity, performance against initial design
Policy for inspection plant and equipment and updated following
appointment deficiencies and intent.
and maintenance change / modification
Asset register abnormal conditions.
and ageing plant Improvements
Asset inspection
strategy, including Risk assessment Delivery of inspection and replacement
and maintenance
any lifetime drives inspection and and maintenance programme in place to
programme
extensions maintenance programme programme closely deal with ageing assets
implemented to plan
monitored and technological
Policy for critical Intelligent customer
Critical items advancesPlanning and
spares approach to procurement Failure modes and
prioritised review of resources
of plant, equipment and underlying causes of
Policy for
services Approved contractor/ asset failures reported Top management
identification of
supplier index and investigated review reports
critical plant / Strategic planning for
equipmentPolicy/ outsourcing Interview with Audit outcomes Interviews with senior
process for contractors/suppliers management
Risk profiling Contractor
outsourcing and
Risk assessment and performance Continual improvement
the procurement of Evidence of consultation
operational control monitoring of OHSMS
goods and services with contractors during
sampling (interview
appointment process Process safety plan Primary related
Policy/process and observation)
monitoring elements
for the approval, Defined roles and
Permit to work process (5.01)(5.02)(5.03)
appointment and responsibilities Permit to work
management of sampling
sampling
contractors/suppliers Inclusion of outsourcing
Evidence of contractor
and contractor Non-conformance
Commitment to understanding and
appointment within reviews
provision of resource awareness of OH&S
change management
within policy issues Management reports
plans and resource
statement consideration process Primary related Accident/ill health
Defined roles and elements analysis
Primary related
responsibilities (3.01)(3.02)(3.08)
elements Primary related
(3.20)
Evidence of (2.03)(2.04)(2.06)(2.07) elements
consultation with (2.10) (4.02)(4.03)(4.04)
contractors during (4.05)(4.07)(4.08)
appointment process (4.09)

Primary related
elements
(1.01)(1.03)(1.06)
(1.10)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 16
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Risk assessment and Commitment to Structured hazard Risk assessment External accreditation External accreditation
operational control a process of risk identification and (sampling) and (statutory and
Records of top
control within policy risk assessment evidence of alignment otherwise)
management review
statement methodologies adopted with, plant design, safe
Management reports
eg HAZOPs, QRA, operating parameters, Evidence of legislative
Policy for periodic
LOPA studies. SOPs and incident Audit and inspection updates to OHSMS
process safety
reports records
hazard reviews Risk and consequence Management meeting
modelling used to Effective Non-conformance records
Policy/process for
inform design, control implementation of monitoring
risk management/ Primary related
measures and mitigation controls (observation
assessment and objective monitoring elements
and interview)
control Risks to be reduced All elements
to ALARP Training records Statutory compliance
within this section
Defined roles and records
responsibilities Planning for risk Maintenance records
profiling, hazard Accident investigations
Process for Statutory examination
and opportunity Health surveillance
stakeholder records
identification, records
involvement in risk
management and control Inspection records
management and Primary related
control Risk/hazard matrix/ Evacuation drill elements
index/register records (4.02)(4.03)(4.04)
Primary related
elements Planning for provision of (4.05)(4.06)(4.09)
Permit to work records
(1.01)(1.02)(1.03) suitable resources and (4.12)
(1.04)(1.05)(1.06) support Primary related
(1.10) elements
Change management All elements
planning within section

Training schedules

Business recovery
planning

Primary related
elements
(2.03)(2.04)(2.05)(2.06)
(2.07)(2.08) (2.09)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 17
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Emergency incident Commitment to Business recovery/ Evidence of emergency Review of evacuation Records of management
planning manage emergency emergency planning procedure testing (fire tests review of OHSMS
events, staff welfare drills, environmental
Emergency procedure Loss/damage analysis Improved emergency
etc. incidents, recovery
planning – on-site and planning and
tests, etc.) Audit and inspection
Emergency off-site arrangements
reports
management policy/ Stakeholder awareness
Risk assessment process Evidence of legislative
process (interviews) Primary related
updates to OHSMS
Training/competency elements
Policy of co- Signage (escape
matrix (4.02)(4.03)(4.04) Primary related
operation and routes etc.)
(4.05)(4.09) elements
integration with Process safety plan
Provision of equipment (5.01)(5.02)(5.03)
external emergency
Process safety objectives (fire extinguishers, first
services
aid etc.)
Defined roles and Change management
planning Inspection and
responsibilities
maintenance records
Competency policy/ Primary related
elements Training records
process
(2.03)(2.04)(2.05)(2.06)
Risk assessment
Consultation with (2.07)(2.08)(2.09)
sampling
and participation
of relevant Primary related
stakeholders in elements
development of (3.01)(3.02)(3.03)
arrangements (3.08)(3.14)(3.17)
(3.18)(3.21)(3.22)
Primary related
elements
(1.01)(1.02)(1.03)
(1.04)(1.05)(1.06)
(1.07)(1.10)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 18
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Development and Commitment Training matrix/ Evidence of Staff surveys Stakeholder
maintenance of a to develop and programme stakeholder involvement in OHSMS
OH&S objectives
positive health and continually improve involvement, reviews
CPD development and monitoring
safety culture empowerment
Policy/process appraisal External accreditation
and management Accident/incident
for competency,
Mentoring and coaching commitment analysis and reports Forward planning and
consultation and
(interviews and objective setting
communication Process safety objectives Management reports
observation)
Appraisal reviews
Defined roles and Specific development Plan monitoring
Minutes from health
responsibilities programmes Corporate reports
and safety meetings External accreditation
Process for Terms of reference for Primary related
Training records Evidence of
stakeholder health and safety (and elements
consultation and Audit reports stakeholder
other) forums All elements
participation participation in
within section
Occupational health Stakeholder surveys performance reviews
Evidence of top and wellbeing plans/
Inspection reports Contractor approval
management programmes
commitment and records
Change management
ownership Planning for participation
plans Review of training
of stakeholders in
Primary related needs
development of OHSMS Risk assessment
elements sampling Review of health
(1.02)(1.03)(1.04) Occupational health
surveillance records
(1.05)(1.06)(1.07) support programmes and Appraisal and
(1.10) planning development records Primary related
elements
Primary related Primary related
(4.01)(4.02)(4.04)
elements elements
(4.06)(4.07)(4.08)
All elements (3.01)(3.02)(3.06)
(4.09)(4.10)(4.12)
within section (3.19)(3.20)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 19
8. Specification guidance cont.

Plan Do Check Act

Subject area S1: Organisational S2: Strategic planning S3: Implementation S4: Performance S5: Management
Commitment and (1,125 points) and operation evaluation review and
structure (1,500 points) (1,125 points) improvement
(750 points) (500 points)
Proactive and Policy/process OH&S plan Stakeholder Accident/incident Records of top
reactive performance for performance understanding and analysis management review
Procedures/processes/
measurement monitoring awareness of process
plans for: Ill health and objective review and
safety management
Commitment absenteeism reviews forward planning
Auditing system (interview)
to continual
OH&S plan reviews External accreditation
improvement Inspection Audit records
(planning and review)
within policy MAPP Management reports
Accident investigation Inspection records
statement Corporate reports
Website/corporate
Ill health monitoring Accident/incident
Defined roles and information and Primary related
records
responsibilities Process for assessment reporting elements
of OHSMS including PTW documents All elements
Commitment Process safety
benchmarking (internal within section
to legislative Contractor induction objective monitoring
compliance within and/or external)
records
policy statement Audit records
Incident/loss/near miss/
Approved contractor/
Process for non-conformance External accreditation
supplier index
stakeholder reporting
Statutory records
consultation and Risk assessment(s)
Contractor/supplier
participation sampling Review of training
monitoring
records and
Primary related Site inspection
Training plan effectiveness of
elements Health and safety training content
(1.01)(1.02)(1.03) Risk assessment
meeting minutes
(1.05)(1.06)(1.10) planning Primary related
Notice board elements
Primary related
information All elements
elements
within section
(2.01)(2.02)(2.03)(2.04) Statutory records
(2.07)(2.10)
Staff surveys

Training records

Primary related
elements
(3.01)(3.02)(3.08)
(3.19)(3.20)

© British Safety Council 2017 Five Star Process Safety Audit specification 2017 20
No-one should
be injured or
made ill at work.

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© British Safety Council Five Star Audit Specification Document 2013 22