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Refinery Process Safety Management (PSM) Checklist

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Audit a petroleum refinery or gas processing facility against the 14 elements of the OSHA Process Safety Management standard for highly hazardous chemicals.

OSHA 29 CFR 1910.119API RP 750API RP 754CCPS PSM

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Process Safety Information & Employee Participation

  • Is complete written process safety information compiled covering hazards, technology, and equipment? *
  • Are safety data sheets, P&IDs, and design codes/standards documented and current? *
  • Is a written employee participation plan in place and are employees consulted on PHAs? *

Process Hazard Analysis

  • Has a PHA been performed for each covered process using an appropriate methodology (HAZOP, What-If, FMEA)? *
  • Is the PHA revalidated at least every five years? *
  • Are PHA recommendations resolved, documented, and tracked to completion? *
  • Date of the most recent PHA or revalidation. *

Operating Procedures & Training

  • Are written operating procedures maintained for each phase (startup, normal, temporary, shutdown, emergency)? *
  • Have operators received initial and refresher training on the process and procedures? *
  • Are safe work practices for hot work, lockout/tagout, and confined space entry documented and enforced? *

Mechanical Integrity & Contractors

  • Is a mechanical integrity program in place with inspection and testing schedules for critical equipment? *
  • Are equipment deficiencies corrected or managed before continued use? *
  • Are contractors evaluated for safety performance and informed of process hazards? *

Management of Change & PSSR

  • Is a management of change (MOC) procedure applied to process chemicals, technology, equipment, and procedures? *
  • Is a pre-startup safety review (PSSR) conducted for new and modified facilities? *
  • Are temporary changes tracked and returned to original design conditions or formally made permanent through MOC? *

Incident Investigation, Emergency Response & Audits

  • Are incidents that resulted in or could have resulted in a catastrophic release investigated within 48 hours? *
  • Is an emergency action plan established and coordinated with local responders? *
  • Is a compliance audit of the PSM program conducted at least every three years? *

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