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Oil Refinery Process Safety Management (PSM) Audit Checklist

A comprehensive checklist for auditing Process Safety Management (PSM) systems in oil refineries, covering all elements of OSHA's PSM standard and best practices in process safety.

Oil Refinery Process Safety Management (PSM) Audit Checklist

by: audit-now
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About This Checklist

Process Safety Management (PSM) is crucial for preventing catastrophic incidents in oil refineries. This comprehensive PSM audit checklist is designed to evaluate the effectiveness of a refinery's process safety systems, procedures, and practices. By conducting thorough PSM audits, refineries can identify potential hazards, assess risk control measures, and ensure compliance with OSHA's PSM standard. Regular PSM audits are essential for maintaining operational integrity, protecting workers, and safeguarding surrounding communities.

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Industry

Energy and Utilities

Standard

OSHA PSM 1910.119

Workspaces

Oil refineries

Occupations

Process Safety Engineer
PSM Coordinator
Safety Manager
Operations Supervisor
Compliance Specialist
1
Is there a documented hazard analysis for the processes in the facility?
2
Are management of change procedures in place and followed?
3
What is the average number of training hours provided to employees on process safety management?
Min: 0
Target: 40
Max: 100
4
Are mechanical integrity inspections performed and documented regularly?
5
Provide details of any process safety incidents that occurred in the last year.
6
Is there an established and practiced emergency response plan for process safety incidents?
7
How often are risk assessments conducted for high hazard processes?
Min: 1
Target: 12
Max: 12
8
Are process safety management system reviews conducted at scheduled intervals?
9
Describe how safety information is communicated to employees.
10
When was the last safety audit conducted?
11
Is the process hazard analysis reviewed and updated regularly?
12
How many hours were dedicated to the maintenance of safety equipment in the last quarter?
Min: 0
Target: 20
Max: 100
13
Are safety meetings held regularly to discuss process safety issues?
14
Describe how management demonstrates commitment to process safety.
15
When was the last process safety training conducted for employees?
16
Are there established procedures for investigating process safety incidents?
17
What percentage of safety audit findings from the last audit have been resolved?
Min: 0
Target: 90
Max: 100
18
Is safety equipment tested regularly to ensure functionality?
19
Provide insights on employee feedback regarding the safety culture in the workplace.
20
When was the last review of the process safety management system conducted?
21
Are safety performance metrics established and monitored?
22
What is the total number of safety incidents reported in the last year?
Min: 0
Target: 5
Max: 1000
23
Are regular safety drills conducted to prepare for emergencies?
24
Describe how the company's safety policies are communicated to employees.
25
When was the last safety inspection of critical equipment conducted?

FAQs

The checklist covers all 14 elements of OSHA's PSM standard, including process hazard analysis, operating procedures, mechanical integrity, management of change, and employee participation.

OSHA requires that compliance audits be conducted at least every three years, but many refineries conduct more frequent internal audits to ensure ongoing compliance and safety.

PSM audits should involve a cross-functional team including process safety engineers, operations personnel, maintenance staff, and sometimes third-party PSM experts to ensure a comprehensive evaluation.

By systematically evaluating all aspects of the PSM program, the checklist helps identify areas for improvement, ensures regulatory compliance, and supports the development of robust safety systems and practices.

Audit findings should be thoroughly documented, shared with management, used to develop corrective action plans, and incorporated into the refinery's continuous improvement processes for process safety.

Benefits of Oil Refinery Process Safety Management (PSM) Audit Checklist

Ensures compliance with OSHA's Process Safety Management standard

Identifies gaps in process safety systems and procedures

Helps prevent major incidents and minimizes operational risks

Promotes a culture of safety and continuous improvement

Enhances overall refinery reliability and operational efficiency