COSHH and Process Safety Documentation for a Chemical Manufacturing Facility

The Challenge

The facility had been operating for over 20 years, and while frontline operatives were experienced and competent, the supporting documentation had not kept pace with regulatory developments or changes to processes and substances used. Key challenges included:

• Ageing COSHH assessments that no longer reflected current substances, exposure levels, or control measures
• Multiple hazardous substances in use across different process areas without a consolidated assessment framework
• Standard Operating Procedures (SOPs) that lacked detail on emergency response and spill containment
• An upcoming HSE inspection with potential for enforcement action if documentation was found to be inadequate
• Limited internal HSE resource to conduct a comprehensive re-assessment programme

Our Approach

Operational Assurance Group was engaged to conduct a full COSHH re-assessment programme and update the site's SOP library. Our work included:

• Site walkdown and consultation with process operators to understand current working practices and substance handling
• Comprehensive COSHH assessment for all hazardous substances, including exposure risk evaluation and control hierarchy application
• Development of substance-specific emergency spill response plans and environmental containment procedures
• Updating of SOPs to include clear task sequences, PPE requirements, and emergency actions
• Creation of a COSHH register and substance management framework for ongoing compliance
• Delivery of briefings to site management and supervisors on the updated documentation

All documentation was produced to current HSE guidance and structured for regulatory audit compliance. We ensured that assessments were evidence-based, controls were proportionate, and procedures were usable by the site team.

Outcomes

The engagement delivered regulatory compliance and operational confidence:

• Regulatory audit passed with no enforcement notices or improvement requirements
• HSE inspector commended the quality and comprehensiveness of COSHH documentation
• Documentation suite adopted as the site standard and integrated into the site's management system
• Improved operator awareness of hazardous substance risks and control measures
• Spill response plans tested and validated during site emergency drills

The client now has a robust, audit-ready COSHH framework that protects workers, satisfies regulatory requirements, and supports continuous improvement in occupational health management.