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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 Process Safety Management Standard (29 CFR 1910.119) - Mechanical Integrity Element

Workspaces

Chemical processing plants
refineries
and manufacturing facilities

Occupations

Process Safety Engineer
Maintenance Manager
Reliability Engineer
PSM Coordinator
Equipment Inspector

Equipment Integrity Assessment

(0 / 5)

1
What is the plan for managing and addressing equipment deficiencies?

Describe the deficiency management plan.

To assess the approach taken for managing equipment issues.
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2
Have all maintenance personnel received proper training?

Select 'true' if training has been completed.

To ensure that personnel are qualified to handle equipment safely.
3
Are the inspection records for the equipment up-to-date?

Provide details about the latest inspections.

To confirm that all inspections are documented and current.
4
What is the frequency of preventive maintenance performed on the equipment?

Enter frequency in months.

To evaluate the effectiveness of maintenance programs.
Min: 1
Target: Monthly
Max: 12
5
Is the mechanical integrity of the process equipment compliant with OSHA standards?

Select compliance status.

To ensure adherence to safety regulations and prevent accidents.
6
What corrective actions were taken in response to any deficiencies found during testing?

Describe the corrective actions implemented.

To understand how issues are resolved to maintain equipment integrity.
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7
Is there documentation available for the testing procedures followed?

Provide details about the documentation.

To ensure that testing methods are standardized and documented.
8
What was the score or outcome of the last equipment test?

Enter the test score as a percentage.

To assess the reliability and performance of the equipment.
Min: 0
Target: 80
Max: 100
9
When was the last testing of the equipment conducted?

Select the date of the last test.

To verify the recency of testing efforts for safety evaluations.
10
Is the testing of process equipment compliant with established procedures?

Select testing compliance status.

To ensure that equipment testing aligns with safety and operational standards.
11
What improvements have been implemented to enhance equipment reliability?

Describe the improvements made.

To assess proactive measures taken to ensure long-term reliability.
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12
Has the scheduled maintenance plan been adhered to?

Select 'true' if maintenance was adhered to.

To ensure that maintenance schedules are followed to enhance reliability.
13
Is there a failure analysis report available for the equipment?

Provide details about the failure analysis report.

To confirm that failures are analyzed to improve reliability.
14
What is the mean time between failures for the equipment?

Enter MTBF in hours.

To evaluate the reliability and maintenance effectiveness of the equipment.
Min: 0
Target: 200
Max: 10000
15
Is the reliability of the equipment in compliance with industry standards?

Select reliability compliance status.

To ensure that equipment operates reliably and meets performance expectations.
16
What lessons have been learned from past incidents involving this equipment?

Describe the lessons learned from incidents.

To assess how past experiences are used to improve safety measures.
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17
Is there an emergency response plan in place for incidents involving this equipment?

Provide details about the emergency response plan.

To confirm that preparedness measures are established to handle emergencies.
18
How many safety incidents involving this equipment have been reported in the last year?

Enter the number of reported safety incidents.

To evaluate the safety performance and identify areas for improvement.
Min: 0
Target: 0
Max: 100
19
When was the last safety audit conducted on the equipment?

Select the date of the last safety audit.

To ensure audits are performed regularly to maintain safety compliance.
20
Is the equipment compliant with the safety standards established by OSHA?

Select safety compliance status.

To ensure that the equipment meets all necessary safety regulations for operation.
21
What feedback has been provided by maintenance personnel regarding the maintenance process?

Describe the feedback from maintenance personnel.

To gather insights from personnel who execute maintenance activities for continuous improvement.
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22
Is a maintenance management system utilized to track maintenance activities?

Select 'true' if a maintenance management system is in use.

To ensure that maintenance activities are systematically tracked and managed.
23
Are the qualifications of the maintenance personnel documented and up-to-date?

Provide details regarding personnel qualifications.

To confirm that maintenance staff are properly qualified to perform their duties.
24
What is the completion rate of scheduled maintenance tasks over the past year?

Enter the completion rate as a percentage.

To evaluate the effectiveness and adherence to the maintenance schedule.
Min: 0
Target: 95
Max: 100
25
Is the preventive maintenance program for the equipment compliant with industry standards?

Select preventive maintenance compliance status.

To ensure that preventive maintenance practices are consistently applied to enhance equipment reliability.

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

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