Spill Prevention & Secondary Containment Checklist

This comprehensive spill prevention & secondary containment checklist helps teams maintain regulatory compliance and operational control against API RP 75, OSHA 29 CFR 1910.119 (PSM), and related requirements. Designed for Operations Supervisor / HSE Lead, complete all sections, capture evidence, and log corrective actions to reduce risk and improve readiness.

Industry: Oil & Gas
Frequency: Weekly
Estimated Time: 25-45 minutes
Role: Operations Supervisor / HSE Lead
Total Items: 35
Compliance: API RP 75, OSHA 29 CFR 1910.119 (PSM), API RP 54, NFPA 51B

Permit to Work & JSA

Confirm permits, JSA, and authorization are complete before work starts.

Permit to Work issued, current, and displayed?
Job Safety Analysis completed and communicated to crew?
SIMOPS / simultaneous operations reviewed (if applicable)?
LOTO/isolations identified and verified?
Notes / permit exceptions

Process Safety & Operating Limits

Verify key process safety barriers and operating limits.

Critical alarms/interlocks in service (no unauthorized bypass)?
Pressure relief devices inspection status current?
Operating parameters within safe limits (pressure/temp/level)?
MOC followed for any temporary changes?
Record key parameter or log reference

Hot Work & Ignition Source Control

Manage ignition sources and fire risk during hot work.

Hot work permit active with fire watch assigned?
Gas testing completed and within limits?
Combustibles cleared or protected; blankets in place?
Fire extinguishers and hose lines available?
Photo of hot work setup

Confined Space Entry

Verify confined space controls including atmospheric testing and rescue readiness.

Entry permit issued and posted?
Atmospheric testing completed and recorded?
Ventilation and isolation in place?
Rescue plan and equipment ready (tripod, retrieval)?
Attendant present and communications working?

Lifting & Rigging Operations

Ensure lifting equipment and plans meet requirements and controls are applied.

Lift plan completed for critical lifts?
Cranes/hoists inspected and certifications current?
Rigging inspected (slings, shackles, hooks) before use?
Exclusion zone established and spotter assigned?
Record any defects or stop-work triggers

Hazardous Materials, Storage & TDG

Confirm chemicals are stored, labeled, and transported safely.

Containers labeled and SDS accessible?
Secondary containment and segregation applied?
Transfer hoses and fittings inspected; no leaks?
TDG documentation complete for shipments (if applicable)?
Spill response equipment ready in area?

Emergency Response & Reporting

Verify emergency readiness, drills, and incident management.

Emergency shutdown routes and egress clear?
Fire/gas detection status normal and tested per schedule?
Muster points and accountability procedures understood?
Incident/near-miss reporting completed for last shift?
Corrective action status reviewed and updated?

Related Oil & Gas Checklists

Related Regulatory Checklists

Why Use This Spill Prevention & Secondary Containment Checklist?

This spill prevention & secondary containment checklist helps oil & gas teams maintain compliance and operational excellence. Designed for operations supervisor / hse lead professionals, this checklist covers 35 critical inspection points across 7 sections. Recommended frequency: weekly.

Ensures compliance with API RP 75, OSHA 29 CFR 1910.119 (PSM), API RP 54, NFPA 51B. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Spill Prevention & Secondary Containment Checklist cover?

This checklist covers 35 inspection items across 7 sections: Permit to Work & JSA, Process Safety & Operating Limits, Hot Work & Ignition Source Control, Confined Space Entry, Lifting & Rigging Operations, Hazardous Materials, Storage & TDG, Emergency Response & Reporting. It is designed for oil & gas operations and compliance.

How often should this checklist be completed?

This checklist should be completed weekly. Each completion takes approximately 25-45 minutes.

Who should use this Spill Prevention & Secondary Containment Checklist?

This checklist is designed for Operations Supervisor / HSE Lead professionals in the oil & gas 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.