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      1 Policy. A written policy providing direction on when, where, and how hazard analyses and risk assessments are performed, including the design phase, should be implemented and communicated. The policy should define roles, responsibilities, and accountabilities for engineers, designers, production, maintenance, quality, legal, SH&E, human resources, procurement, and other involved parties in the design safety process.

      2 Team. A leader and cross‐functional team to perform the design safety review should be selected. Design safety review team members should have expertise in areas such as safety and health, ergonomics and human factors engineering, environmental safety, fire prevention and protection, and product liability prevention as appropriate for the project. Production, maintenance, and/or operator experience is important so that lessons learned from a similar situation (work‐as‐done) can be brought into the design (work‐as‐imagined). It may be necessary to include outside consultants or specialists to assist in the review.

      1 Method selection. Specific methods should be selected for conducting the design safety review based on the complexity of the project, and the established context.

      2 Safety review. In the conceptual stages, a hazard analysis and risk assessment should be initiated to identify hazards. Design safety reviews should be performed as the design objectives are being discussed. Reviews may include analysis of similar designs, plan drawings, specifications and limitations, hazard checklists, applicable standards, discussions with manufacturers of components and materials, safety data sheets (SDSs), loss experience related to similar designs, existing controls and technology on similar designs, etc. The review should assess hazards/risks in the operational phase as well as any nonroutine activities such as maintenance, emergency upsets and repairs, testing, adjusting, lubricating, and other related activities.

      3 Deviations approval. Established safety standards and specifications should be strictly followed. An example of design safety specifications is provided in Table 4. For any deviation from a stated standards or specifications, appropriate management personnel including OSH, legal, or other parties must review the request and determine if it is approved or denied.

      4 Completion signoff. Upon completion, the project leader should sign‐off on the project that the design safety review has been completed and that there is a consensus among the safety team and engineering group. Communication between the design safety review team and engineering/design group throughout the process is critical.

      5 Action plan. Findings and recommendations from the completed design safety review may include modifications or mark‐ups of drawings; changes in specifications; a prioritized list of specific hazards and means for avoidance or control; a list of design modifications necessary prior to approval; action item list with assigned responsibilities; follow up questions, concerns or requests for additional information necessary to satisfy or complete the review and approve the design.