Gas Processing Plant Operational Safety Inspection Checklist
Gas processing plants handle large volumes of flammable hydrocarbons under pressure, creating significant process safety risks. This monthly inspection verifies operational safety controls per OSHA PSM 29 CFR 1910.119.
- Industry: Oil & Gas / Energy
- Frequency: Monthly
- Estimated Time: 45-60 minutes
- Role: Operations Supervisor / PSM Coordinator
- Total Items: 31
- Compliance: OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous Chemicals, API RP 14C - Analysis, Design, Installation and Testing of Safety Systems, NFPA 59A - Standard for the Production, Storage, and Handling of LNG, EPA 40 CFR Part 68 - Risk Management Program
Process Unit Conditions
Verify all process units operating normally.
- All process units operating within normal operating limits (NOL)?
- No unauthorized safety system bypasses?
- Process trend data reviewed and no anomalous trends?
- All pressure gauges readable and within normal range?
- All level gauges readable with liquid levels within normal range?
Amine Treating Unit (if applicable)
Inspect amine treating unit.
- Amine solution concentration within operating specification?
- H2S and CO2 removal efficiency meeting spec?
- No amine foaming indicators (high dP in absorber, loss of absorption)?
- Amine regeneration reboiler temperature within limits?
- Amine solution filters within replacement schedule?
Cryogenic and NGL Systems
Inspect cryogenic safety systems.
- Cold box and heat exchangers showing no frost or insulation damage?
- NGL storage tanks within pressure and temperature operating ranges?
- Turboexpander or JT valves operating correctly?
- Cryogenic PPE available for personnel working near low-temperature equipment?
- Flare system operational and flame stable?
Fire and Gas Detection
Verify fire and gas systems.
- All fixed combustible gas and H2S detectors operational?
- Flame and heat detectors functional?
- Deluge system for pump areas and process vessels functional?
- Foam system for NGL tank areas operational?
- Firewater pumps tested within schedule?
Pressure Relief and Flare System
Verify pressure relief and flare integrity.
- All pressure relief valves within test date per API 520/521?
- No pressure relief valves simmering (blowing) indicating overpressure?
- Flare tips functional with adequate flame and no flare tip damage?
- Flare knockout drum level within normal range?
- Relief valve documentation (datasheets, inspection records) current?
Documentation and PSM
Verify PSM and operations documentation.
- Current operating procedures accessible in control room?
- PHA current with no overdue high-priority action items?
- Mechanical integrity inspections current per PSM schedule?
- No unauthorized changes made without MOC review?
- No unresolved process incidents or near-misses?
- Monthly plant safety inspection report completed?
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Why Use This Gas Processing Plant Operational Safety Inspection Checklist?
This gas processing plant operational safety inspection checklist helps oil & gas / energy teams maintain compliance and operational excellence. Designed for operations supervisor / psm coordinator professionals, this checklist covers 31 critical inspection points across 6 sections. Recommended frequency: monthly.
Ensures compliance with OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous Chemicals, API RP 14C - Analysis, Design, Installation and Testing of Safety Systems, NFPA 59A - Standard for the Production, Storage, and Handling of LNG, EPA 40 CFR Part 68 - Risk Management Program. Regulatory-aligned for audit readiness and inspection documentation.
Frequently Asked Questions
What does the Gas Processing Plant Operational Safety Inspection Checklist cover?
This checklist covers 31 inspection items across 6 sections: Process Unit Conditions, Amine Treating Unit (if applicable), Cryogenic and NGL Systems, Fire and Gas Detection, Pressure Relief and Flare System, Documentation and PSM. It is designed for oil & gas / energy operations and compliance.
How often should this checklist be completed?
This checklist should be completed monthly. Each completion takes approximately 45-60 minutes.
Who should use this Gas Processing Plant Operational Safety Inspection Checklist?
This checklist is designed for Operations Supervisor / PSM Coordinator professionals in the oil & gas / energy industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.
Can I download this checklist as a PDF?
Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.