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OSHA Process Safety Management (PSM) Mechanical Integrity Audit Checklist

A comprehensive checklist for auditing mechanical integrity programs in chemical facilities to ensure compliance with OSHA's Process Safety Management standard and enhance the reliability and safety of process equipment.

OSHA Process Safety Management (PSM) Mechanical Integrity Audit Checklist

by: audit-now
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About This Checklist

Mechanical integrity is a critical element of Process Safety Management (PSM) in the chemical industry, ensuring that equipment and systems operate reliably and safely. This OSHA PSM Mechanical Integrity Audit Checklist is designed to evaluate compliance with the mechanical integrity requirements of OSHA's Process Safety Management standard (29 CFR 1910.119(j)). By assessing inspection, testing, and maintenance procedures for process equipment, this checklist helps identify potential weaknesses in mechanical integrity programs, enhance equipment reliability, and prevent catastrophic failures. Proper implementation of mechanical integrity protocols is essential for maintaining the safety and integrity of chemical processes, preventing releases, and protecting workers and the environment.

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Industry

Chemicals

Standard

OSHA PSM 29 CFR 1910.119

Workspaces

refineries
and manufacturing facilities
Chemical Processing Facilities

Occupations

Process Safety Engineer
Maintenance Manager
Reliability Engineer
PSM Coordinator
Equipment Inspector
1
Is the mechanical integrity of the process equipment compliant with OSHA standards?
2
What is the frequency of preventive maintenance performed on the equipment?
Min: 1
Target: Monthly
Max: 12
3
Are the inspection records for the equipment up-to-date?
4
Have all maintenance personnel received proper training?
5
What is the plan for managing and addressing equipment deficiencies?
6
Is the testing of process equipment compliant with established procedures?
7
When was the last testing of the equipment conducted?
8
What was the score or outcome of the last equipment test?
Min: 0
Target: 80
Max: 100
9
Is there documentation available for the testing procedures followed?
10
What corrective actions were taken in response to any deficiencies found during testing?
11
Is the reliability of the equipment in compliance with industry standards?
12
What is the mean time between failures for the equipment?
Min: 0
Target: 200
Max: 10000
13
Is there a failure analysis report available for the equipment?
14
Has the scheduled maintenance plan been adhered to?
15
What improvements have been implemented to enhance equipment reliability?
16
Is the equipment compliant with the safety standards established by OSHA?
17
When was the last safety audit conducted on the equipment?
18
How many safety incidents involving this equipment have been reported in the last year?
Min: 0
Target: 0
Max: 100
19
Is there an emergency response plan in place for incidents involving this equipment?
20
What lessons have been learned from past incidents involving this equipment?
21
Is the preventive maintenance program for the equipment compliant with industry standards?
22
What is the completion rate of scheduled maintenance tasks over the past year?
Min: 0
Target: 95
Max: 100
23
Are the qualifications of the maintenance personnel documented and up-to-date?
24
Is a maintenance management system utilized to track maintenance activities?
25
What feedback has been provided by maintenance personnel regarding the maintenance process?

FAQs

The main objective is to assess compliance with the mechanical integrity element of OSHA's Process Safety Management standard and evaluate the effectiveness of programs to maintain the integrity of process equipment in chemical facilities.

While OSHA requires that the entire PSM program be audited at least every three years, it's recommended to conduct more frequent reviews of mechanical integrity programs, typically annually or when significant changes occur in equipment or processes.

Key areas include written procedures for maintaining equipment integrity, inspection and testing schedules, equipment deficiency management, quality assurance for critical equipment, training for maintenance personnel, and management of change procedures related to equipment modifications.

The audit should involve a team including process safety engineers, maintenance managers, reliability engineers, and operations personnel who are knowledgeable about the facility's equipment and PSM requirements.

Audit results can identify gaps in maintenance procedures, inspection practices, or documentation, leading to improved preventive maintenance programs, enhanced equipment reliability, better training for maintenance personnel, and ultimately reducing the risk of equipment-related incidents and chemical releases.

Benefits of OSHA Process Safety Management (PSM) Mechanical Integrity Audit Checklist

Ensures compliance with OSHA's PSM Mechanical Integrity requirements

Reduces the risk of equipment failures and potential chemical releases

Improves overall reliability and safety of process equipment

Enhances preventive maintenance programs in chemical facilities

Promotes a proactive approach to equipment integrity and process safety