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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?

Select compliance status.

To ensure that hazards are identified and managed properly.
2
Are management of change procedures in place and followed?

Indicate if management of change procedures are in place.

To verify that changes are properly managed to prevent process safety incidents.
3
What is the average number of training hours provided to employees on process safety management?

Enter the average number of training hours.

To assess the level of employee preparedness regarding safety management.
Min: 0
Target: 40
Max: 100
4
Are mechanical integrity inspections performed and documented regularly?

Select the status of mechanical integrity inspections.

To ensure that equipment is maintained in a safe operating condition.
5
Provide details of any process safety incidents that occurred in the last year.

Describe any incidents that occurred.

To evaluate the effectiveness of incident prevention measures.
6
Is there an established and practiced emergency response plan for process safety incidents?

Indicate if an emergency response plan is in place.

To ensure preparedness in case of emergencies related to hazardous processes.
7
How often are risk assessments conducted for high hazard processes?

Enter the frequency of risk assessments (in months).

To assess the frequency of risk evaluations and ensure timely updates.
Min: 1
Target: 12
Max: 12
8
Are process safety management system reviews conducted at scheduled intervals?

Select the review status.

To confirm that the PSM system is reviewed for effectiveness and compliance.
9
Describe how safety information is communicated to employees.

Provide details on safety communication methods.

To evaluate the effectiveness of communication strategies in promoting safety culture.
10
When was the last safety audit conducted?

Select the date of the last safety audit.

To track audit frequency and ensure ongoing compliance with safety standards.
11
Is the process hazard analysis reviewed and updated regularly?

Select the review status of the hazard analysis.

To ensure that the hazard analysis reflects current operations and practices.
12
How many hours were dedicated to the maintenance of safety equipment in the last quarter?

Enter the total maintenance hours for safety equipment.

To evaluate the commitment to maintaining safety equipment in operational condition.
Min: 0
Target: 20
Max: 100
13
Are safety meetings held regularly to discuss process safety issues?

Indicate if safety meetings are held regularly.

To ensure ongoing communication and attention to process safety among employees.
14
Describe how management demonstrates commitment to process safety.

Provide examples of management commitment to safety.

To assess the level of support and resources allocated to process safety management.
15
When was the last process safety training conducted for employees?

Select the date of the last training session.

To ensure that employees receive training on process safety management regularly.
16
Are there established procedures for investigating process safety incidents?

Select the status of incident investigation procedures.

To verify that incidents are thoroughly investigated to prevent recurrence.
17
What percentage of safety audit findings from the last audit have been resolved?

Enter the percentage of resolved audit findings.

To gauge the effectiveness of corrective actions taken after audits.
Min: 0
Target: 90
Max: 100
18
Is safety equipment tested regularly to ensure functionality?

Indicate if safety equipment is regularly tested.

To confirm that safety equipment is operational and reliable.
19
Provide insights on employee feedback regarding the safety culture in the workplace.

Describe employee feedback on safety.

To evaluate employee perceptions and identify areas for improvement in safety culture.
20
When was the last review of the process safety management system conducted?

Select the date of the last process safety review.

To ensure that the process safety management system is reviewed regularly.
21
Are safety performance metrics established and monitored?

Select the monitoring status of safety performance metrics.

To ensure that safety performance is tracked and improvements are identified.
22
What is the total number of safety incidents reported in the last year?

Enter the total number of safety incidents reported.

To assess the overall safety performance and identify trends.
Min: 0
Target: 5
Max: 1000
23
Are regular safety drills conducted to prepare for emergencies?

Indicate if regular safety drills are conducted.

To ensure that employees are prepared for potential emergency situations.
24
Describe how the company's safety policies are communicated to employees.

Provide details on safety policy communication methods.

To evaluate the effectiveness of safety policy dissemination and understanding among employees.
25
When was the last safety inspection of critical equipment conducted?

Select the date of the last equipment safety inspection.

To ensure that critical equipment is inspected for safety compliance regularly.

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

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