Process Safety Management Auditing is a specialised professional training course designed to strengthen the ability of oil and gas organisations to evaluate process safety systems, verify operational controls and identify weaknesses that expose facilities to major accident hazards. The Process Safety Management Auditing Training Course from Institute For Oil & Gas Training equips industry professionals with the knowledge and practical skills required to plan, conduct and report an effective PSM audit across upstream, midstream and downstream operations.
Process safety management is fundamental to protecting personnel, assets, the environment and business continuity in facilities handling flammable substances, toxic chemicals, hydrocarbons and other hazardous materials. Oil refineries, petrochemical plants, offshore installations, gas processing facilities, storage terminals and pipeline networks depend on interconnected safety systems to control hazardous operations. Weaknesses in these systems can contribute to fires, explosions, toxic releases, equipment failures and other major incidents with significant operational and financial consequences.
A structured process safety audit provides organisations with a systematic means of assessing whether established safety management arrangements are properly implemented, consistently maintained and effective in practice. It examines the relationship between written procedures, operational activities, engineering safeguards, workforce competence and management oversight. Rather than concentrating solely on documentation, an effective audit verifies how safety requirements translate into day-to-day operational performance.
The course addresses the skills gap between understanding process safety management requirements and applying a structured audit methodology in complex industrial environments. Participants develop a practical understanding of audit planning, evidence collection, interviews, document reviews, field verification, findings classification, corrective action tracking and reporting. These capabilities support stronger internal assurance and more consistent identification of deficiencies before they contribute to serious incidents.
OSHA 1910.119 compliance is an important consideration for organisations and facilities subject to the United States Occupational Safety and Health Administration's Process Safety Management of Highly Hazardous Chemicals standard. The course explores how auditors assess relevant requirements, verify implementation and document evidence of compliance. It also addresses the importance of distinguishing legal obligations from company procedures, recognised industry practices and other applicable regulatory requirements.
The Process Safety Management Auditing Training Course also considers how audit procedures support continuous improvement across the process safety lifecycle. Participants examine management of change, process hazard analysis, operating procedures, mechanical integrity, contractor management, training, incident investigation, emergency planning and compliance audits. They learn to connect individual findings with wider organisational weaknesses, helping management teams prioritise corrective actions according to risk and operational significance.
Delivered by Institute For Oil & Gas Training, this course provides a corporate-focused approach to process safety assurance. It enables professionals to contribute more effectively to audit programmes, strengthen regulatory compliance, improve the quality of safety evidence and support management decisions that protect people, facilities and business performance.
Explain the purpose, scope and business importance of process safety management auditing in oil and gas operations.
Interpret relevant process safety requirements and establish suitable audit criteria for the facility or organisation under review.
Explain the applicability of OSHA 1910.119 compliance requirements and distinguish regulatory obligations from internal company standards.
Develop risk-based audit plans that define scope, objectives, responsibilities, sampling approaches and evidence requirements.
Apply systematic audit procedures to document reviews, personnel interviews, operational observations and field verification.
Evaluate process safety management elements, including process safety information, hazard analysis, operating procedures, training and mechanical integrity.
Assess management of change, contractor management, incident investigation and emergency planning arrangements.
Identify deficiencies in safety controls and establish evidence-based conclusions against defined audit criteria.
Classify audit findings according to their significance, supporting evidence and potential implications for process safety performance.
Prepare clear audit reports that communicate findings, underlying weaknesses, risk implications and recommended corrective actions.
Evaluate corrective action plans, verify implementation and assess whether completed actions address the identified causes.
Contribute to continuous improvement by integrating audit results into management review, risk reduction and process safety assurance activities.
The training methodology combines structured technical instruction with practical exercises based on process safety management challenges encountered in the oil and gas industry. The emphasis is on applying audit principles to realistic operational situations rather than relying exclusively on theoretical explanations or regulatory summaries.
Participants examine the relationship between process safety requirements, operational controls and evidence of implementation. The delivery approach encourages them to evaluate whether a documented procedure reflects actual site practices and whether the available evidence demonstrates that a safety control operates as intended.
Industry-based case studies illustrate how gaps in process safety management systems develop and how systematic auditing identifies those weaknesses. Scenarios address deficiencies in operating procedures, overdue inspection activities, incomplete management of change records, inadequate contractor oversight and ineffective corrective action closure.
Participants review the available evidence, identify relevant audit criteria and determine which questions require further investigation. These exercises build the ability to distinguish isolated documentation errors from broader weaknesses in the management system.
Participants develop audit plans that define the scope, objectives, criteria, responsibilities and evidence requirements for a process safety audit. Exercises consider facility complexity, hazardous processes, previous findings, operational changes and areas requiring additional scrutiny.
The planning activities demonstrate how risk-based prioritisation directs audit resources towards issues with the greatest potential safety and operational consequences. Participants also examine how to coordinate audit activities with site personnel without compromising operational controls or disrupting essential work.
Document review exercises focus on process safety information, hazard analysis records, operating procedures, inspection records, training documentation, incident investigations and management of change files. Participants evaluate the completeness, relevance and consistency of evidence against established audit criteria.
The methodology emphasises evidence-based conclusions. Auditors must support findings with verifiable records, observations or interview evidence rather than assumptions, personal preferences or unsupported interpretations.
Structured role-play exercises allow participants to practise interviewing managers, engineers, maintenance personnel, operators and contractors. They learn to ask clear questions, explore discrepancies, confirm responsibilities and establish whether personnel understand the controls relevant to their work.
Field verification scenarios reinforce the importance of comparing documented requirements with actual operating conditions. Participants examine how equipment identification, inspection status, access to procedures, control-room practices and work execution provide evidence of process safety implementation.
Participants practise writing findings that identify the requirement, the observed condition, the supporting evidence and the operational significance of the deficiency. Exercises cover the difference between a non-compliance, a control weakness, an improvement opportunity and an observation requiring further verification.
Corrective action workshops focus on root cause analysis, action ownership, completion deadlines, risk-based prioritisation and effectiveness verification. Participants learn why closing an action administratively does not automatically demonstrate that the underlying process safety weakness has been resolved.
Group activities encourage participants to compare audit approaches, evaluate alternative interpretations and discuss the practical challenges of conducting audits in complex facilities. Facilitated feedback reinforces consistency, professional judgement, impartiality and clear communication.
This blended methodology helps participants translate audit principles into repeatable practices that support stronger process safety assurance within their organisations.
The course supports a more systematic approach to evaluating process safety management systems across operational facilities. Participants learn to assess whether critical safety requirements are implemented, documented and supported by appropriate evidence.
Organisations gain a clearer view of weaknesses affecting their safety management arrangements. More consistent audit practices help management teams understand where controls require improvement and where further verification is necessary.
A structured PSM audit helps organisations evaluate their performance against applicable regulatory requirements, recognised standards and internal procedures. For facilities subject to OSHA 1910.119, systematic auditing supports the identification of deficiencies associated with the relevant requirements of the standard.
The course helps participants establish traceable links between audit criteria, evidence, findings and corrective actions. This improves the quality of compliance records and supports more informed preparation for internal reviews and applicable regulatory inspections. Training does not itself certify a facility as compliant or replace legal and technical compliance assessments.
Systematic auditing helps identify gaps in operating procedures, maintenance controls, process hazard analysis, workforce training and management of change arrangements. Early identification gives organisations an opportunity to address deficiencies before they develop into more serious operational problems.
The benefits depend on the quality of audit implementation and the effectiveness of subsequent corrective actions. Organisations strengthen their preventive approach when findings are prioritised according to risk and verified through appropriate follow-up activities.
The course develops a consistent approach to recording audit findings, assigning responsibilities and monitoring action closure. Clearer findings improve accountability by specifying the requirement, evidence of the deficiency and the action needed to address the underlying issue.
Management teams can use measures such as overdue high-priority actions, repeat findings, verified closure rates and recurrence of previously identified deficiencies to evaluate the effectiveness of their audit programmes.
Process safety management systems interact closely with equipment integrity, maintenance planning, operating discipline and change control. Auditing these elements helps organisations identify weaknesses that affect safe and reliable operations.
Stronger oversight of inspection records, equipment deficiencies and operating procedures supports better coordination between process safety, engineering, operations and maintenance teams. This creates a more consistent basis for identifying and managing operational risks.
Risk-based audit planning helps organisations focus attention on areas with significant process hazards, unresolved findings or material changes in operating conditions. Structured evidence collection reduces reliance on inconsistent or repetitive audit activities.
Clear reporting also helps management distinguish urgent deficiencies from lower-priority improvements. This supports more informed decisions about technical resources, corrective action budgets and management attention.
Consistent auditing reinforces the importance of following established procedures, reporting deficiencies and maintaining reliable records. The course supports constructive engagement between auditors and operational teams by emphasising objective evidence, impartiality and clear communication.
When management responds appropriately to findings, auditing becomes a practical mechanism for strengthening accountability and continuous improvement rather than simply fulfilling a documentation requirement.
Participants develop a structured understanding of how to prepare for and conduct a process safety audit. They learn to define audit criteria, gather evidence, interview personnel, verify operational practices and document findings in a consistent manner.
These capabilities strengthen their contribution to internal audits, management system reviews and process safety assurance activities.
The course improves participants' ability to interpret relevant process safety requirements and evaluate their implementation. They develop a clearer understanding of OSHA 1910.119 compliance where applicable, together with the role of recognised standards and internal company procedures.
This knowledge supports more focused discussions with compliance teams, technical specialists and operational managers.
Participants learn to evaluate discrepancies between documented requirements and actual conditions. They develop the ability to identify patterns across findings, distinguish symptoms from underlying weaknesses and ask questions that support reliable conclusions.
These skills improve the quality of audit evidence and help participants recognise issues requiring additional technical investigation.
The course strengthens the ability to communicate audit findings clearly to different audiences. Participants practise presenting evidence, explaining the significance of deficiencies and recommending corrective actions without exaggeration or unsupported conclusions.
Improved reporting supports more effective engagement with senior management, facility leadership and specialist departments.
Participants learn how to assess proposed actions, establish suitable verification criteria and determine whether corrective measures address the identified deficiency. They develop a practical understanding of action tracking, root cause analysis and repeat-finding prevention.
This supports a more effective contribution to the closure and verification stages of the audit process.
The course is relevant to professionals seeking to strengthen their capabilities in process safety, operational risk, health and safety management, engineering assurance and regulatory compliance. The knowledge gained supports greater involvement in audit planning, audit execution, technical reviews and management reporting.
The Certificate of Completion from Institute For Oil & Gas Training provides a record of course participation and completion. It does not represent an independent professional licence or an external auditor accreditation.
Process Safety Engineers: To strengthen their ability to assess process safety management systems and identify weaknesses in critical safeguards.
HSE Managers and Advisers: To improve audit planning, compliance reviews, findings management and process safety assurance.
Operations Managers and Superintendents: To evaluate operational discipline, procedure compliance and the effectiveness of controls within their facilities.
Process Engineers: To examine process safety information, hazard analysis documentation and the implementation of technical safeguards.
Maintenance and Reliability Managers: To assess mechanical integrity arrangements, inspection records, maintenance controls and equipment-related findings.
Internal Auditors: To develop specialist knowledge of process safety audit criteria, evidence collection, reporting and corrective action verification.
Compliance and Regulatory Affairs Professionals: To strengthen their approach to assessing applicable regulatory obligations and maintaining traceable compliance evidence.
Risk Management Professionals: To connect audit findings with process hazards, operational risk assessments and risk reduction priorities.
Technical Safety Specialists: To improve their ability to review safety management arrangements and verify the implementation of risk controls.
Asset Integrity Professionals: To evaluate the relationship between equipment integrity programmes, inspection activities and process safety requirements.
Plant and Facility Managers: To gain greater visibility of process safety weaknesses, audit performance and outstanding corrective actions.
Engineering and Project Managers: To assess how project changes, modifications and commissioning activities interact with management of change and process safety controls.
Incident Investigation Specialists: To examine how audit evidence identifies recurring weaknesses and supports the prevention of similar incidents.
Senior Supervisors and Department Heads: To strengthen their oversight of operational procedures, workforce responsibilities and action closure.
Contractor Management Professionals: To evaluate contractor selection, competence, supervision and adherence to relevant process safety requirements.
Professionals Transitioning into Process Safety Auditing: To establish a practical foundation for supporting audit teams and contributing to structured process safety reviews.
This module establishes the foundations of process safety management auditing and its role in operational assurance across the oil and gas sector. Participants examine the relationship between process hazards, management system requirements, audit objectives and organisational risk.
The module focuses on developing a structured audit approach that defines scope, criteria, responsibilities and evidence requirements. Participants learn how to select audit priorities, review previous findings and establish an appropriate plan for examining process safety management arrangements.
Establishes requirements for managing hazards associated with highly hazardous chemicals in workplaces covered by the standard.
Addresses management system elements including process safety information, process hazard analysis, operating procedures, training and mechanical integrity.
Provides relevant audit criteria for assessing covered facilities against applicable requirements of 29 CFR 1910.119.
Supports the identification of gaps between documented arrangements and implemented process safety practices.
Requires employers covered by the standard to conduct compliance audits at least every three years, with the specific requirements and applicability determined by the standard.
Explain the purpose and scope of process safety management auditing.
Identify the relationship between audit activities, major accident hazard control and operational assurance.
Establish audit objectives, scope, criteria and responsibilities.
Develop an audit plan based on process hazards, previous findings and operational priorities.
Identify relevant documentation, personnel and operational areas for audit sampling.
Explain the applicability of OSHA 1910.119 compliance requirements to covered facilities.
Distinguish regulatory requirements from internal company procedures and improvement recommendations.
This module examines how auditors evaluate the technical information and hazard assessment processes used to identify, understand and control process risks. Participants review the relationship between accurate process information, engineering design, hazard analysis and the selection of appropriate safeguards.
The module also explores how auditors determine whether hazard assessments remain relevant following process modifications, operating changes or the introduction of new equipment. Emphasis is placed on evidence quality, technical traceability and the implementation of actions arising from hazard studies.
Provides guidance for applying Hazard and Operability Studies, commonly known as HAZOP.
Describes a structured approach to examining process deviations, their causes and their potential consequences.
Supports systematic identification of hazards and operability problems during process design and review.
Provides a recognised reference for evaluating the methodology and documentation of relevant hazard studies.
Helps auditors examine whether hazard review records identify credible scenarios and document the basis for required actions.
Assess the completeness and accuracy of relevant process safety information.
Review hazard analysis records for scope, methodology, supporting information and traceability.
Examine how process deviations, causes, consequences and safeguards are documented.
Evaluate whether hazard study recommendations have assigned responsibilities and appropriate follow-up.
Identify weaknesses in hazard analysis records and supporting technical documentation.
Assess the relationship between process modifications and the need to review existing hazard assessments.
Document evidence-based findings relating to process safety information and hazard analysis.
This module focuses on the systems that maintain safe operating conditions throughout the lifecycle of an oil and gas facility. Participants examine how auditors assess operating procedures, workforce training, mechanical integrity, equipment inspection, maintenance activities and contractor management.
The module also addresses management of change and the controls required when modifications affect process technology, equipment, procedures or personnel responsibilities. Participants learn to compare documented requirements with operating practices and verify whether changes are appropriately assessed, authorised and implemented.
Provides process safety performance indicators for the refining and petrochemical industries.
Establishes a framework for categorising and evaluating process safety events using defined indicator levels.
Supports the use of process safety performance data to identify trends and evaluate improvement priorities.
Helps auditors examine whether organisations monitor relevant process safety events and use findings to strengthen controls.
Complements management system auditing by providing a performance perspective on process safety outcomes.
Audit operating procedures for completeness, accuracy and consistency with established operational requirements.
Evaluate training and competency records relevant to process safety responsibilities.
Review mechanical integrity arrangements, inspection documentation and maintenance records.
Identify evidence of overdue inspections, unresolved equipment deficiencies or inadequate follow-up.
Examine contractor management controls relevant to process safety performance.
Assess management of change documentation, including technical review, authorisation and implementation.
Use relevant process safety performance indicators to support audit analysis and management reporting.
Develop findings that connect observed operational deficiencies with applicable audit criteria.
This module develops the practical skills required to execute a process safety audit consistently and professionally. Participants examine techniques for conducting opening meetings, reviewing records, interviewing personnel, observing work activities and verifying the implementation of operational controls.
The module also addresses evidence evaluation and findings classification. Participants practise developing clear, defensible conclusions that distinguish confirmed non-compliance from broader control weaknesses and improvement opportunities. Particular attention is given to impartiality, traceability and the importance of supporting every material finding with reliable evidence.
Provides guidelines for auditing management systems.
Addresses audit principles including integrity, fair presentation, due professional care, confidentiality and independence where applicable.
Covers audit programme management, audit planning, audit execution and auditor competence.
Supports systematic evidence collection, evaluation and reporting.
Provides a recognised framework for improving the consistency and reliability of management system audits.
Conduct structured audit interviews with operational and technical personnel.
Apply document review, observation and field verification techniques.
Evaluate the relevance, reliability and sufficiency of audit evidence.
Compare actual practices with applicable requirements and defined audit criteria.
Identify and classify process safety deficiencies using consistent, evidence-based methods.
Write findings that explain the requirement, observed condition and supporting evidence.
Maintain impartiality and professional judgement when evaluating conflicting information.
Communicate findings clearly during audit discussions and closing meetings.
This module examines the final stages of the audit process, from consolidating findings to reporting results and verifying corrective action effectiveness. Participants learn how to communicate process safety weaknesses in a way that supports timely management decisions and clear accountability.
The module also explores root cause analysis, action prioritisation, management review and the use of audit trends to strengthen process safety performance. Participants examine how repeat findings, overdue actions and ineffective corrective measures indicate weaknesses in the wider management system and require further investigation.
Specifies requirements for occupational health and safety management systems.
Addresses organisational responsibilities, operational controls, performance evaluation and continual improvement.
Includes requirements relating to incident investigation, corrective action and evaluation of occupational health and safety performance.
Supports systematic management review and the evaluation of management system effectiveness.
Provides a recognised reference for examining how corrective actions and improvement processes are managed within an applicable occupational health and safety management system.
Prepare structured audit reports that communicate scope, criteria, findings and conclusions.
Explain the operational and process safety implications of significant audit deficiencies.
Prioritise corrective actions according to risk, urgency and potential consequences.
Evaluate root cause analysis and determine whether proposed actions address underlying weaknesses.
Establish suitable responsibilities, target dates and verification requirements for corrective actions.
Verify action completion and assess whether implemented measures are effective.
Identify repeat findings and analyse trends across audit results.
Present audit outcomes to management and support informed decisions on risk reduction.
Recommend improvements to audit programmes, reporting arrangements and process safety assurance practices.
Participants who successfully complete the Process Safety Management Auditing Training Course receive a Certificate of Completion from Institute For Oil & Gas Training.
The certificate confirms completion of the training programme and provides a record of professional development in process safety management auditing. It is not a substitute for any separate professional qualification, statutory authorisation or externally accredited auditor certification.
Attendance is required throughout the course in accordance with Institute For Oil & Gas Training's completion requirements. Participants must meet the institute's applicable attendance requirement to receive the Certificate of Completion.
Fees include tuition, course materials and refreshments. Need different dates or a different city? Ask about your preferred date.
The Process Safety Management Auditing Training Course is a professional development programme that teaches participants how to plan, conduct, document and follow up process safety audits. It covers audit criteria, evidence collection, regulatory compliance, process hazard analysis, operating procedures, mechanical integrity, management of change and corrective action verification.
The course is designed for process safety engineers, HSE professionals, internal auditors, operations managers, maintenance and reliability specialists, compliance personnel, technical safety professionals and other staff responsible for process safety management or operational assurance in the oil and gas industry.
Yes. The course examines the OSHA Process Safety Management of Highly Hazardous Chemicals standard, 29 CFR 1910.119, and its relevance to process safety auditing. Participants learn how to assess applicable requirements, review supporting evidence and identify deficiencies. The applicability of individual requirements depends on the facility and the circumstances covered by the standard.
Institute For Oil & Gas Training uses a practical, industry-focused delivery approach incorporating technical instruction, case studies, audit planning exercises, document reviews, interview simulations, field verification scenarios and corrective action workshops. These activities help participants apply audit principles to realistic process safety management situations.
Yes. Participants who meet the attendance and completion requirements receive a Certificate of Completion from Institute For Oil & Gas Training. The certificate confirms completion of the training programme and does not constitute an external auditor accreditation or professional licence.
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Next: 19 Oct 2026
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