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Chemical Plant Process Safety Management (PSM) Audit Checklist

A comprehensive audit checklist designed to evaluate and improve process safety management practices in chemical manufacturing plants, ensuring compliance with PSM regulations and industry best practices.

Chemical Plant Process Safety Management (PSM) Audit Checklist

by: audit-now
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About This Checklist

The Chemical Plant Process Safety Management (PSM) Audit Checklist is an indispensable tool for ensuring the safety and integrity of chemical manufacturing processes. This comprehensive checklist addresses critical aspects of process safety, including hazard analysis, operating procedures, mechanical integrity, and emergency planning. By implementing this audit checklist, chemical plants can identify potential process risks, improve safety systems, and maintain compliance with PSM regulations, ultimately reducing the likelihood of incidents and promoting a robust safety culture in chemical manufacturing operations.

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Industry

Chemicals

Standard

OSHA PSM 1910.119

Workspaces

Chemical Processing Facilities

Occupations

Process Safety Engineer
Chemical Plant Manager
Safety Compliance Officer
Operations Supervisor
Maintenance Manager
1
Is there a documented hazard analysis process in place?
2
Are mechanical integrity procedures implemented and followed?
3
How often is emergency planning training conducted (in months)?
Min: 1
Target: 6
Max: 12
4
Are incident prevention measures documented and reviewed regularly?
5
What feedback have you received regarding the safety culture in the plant?
6
Are the operating procedures reviewed and updated regularly?
7
Describe the process for investigating incidents when they occur.
8
What is the percentage of personnel that have completed PSM training?
Min: 0
Target: 100
Max: 100
9
Is there an emergency response team available at all times?
10
What suggestions do you have for improving safety in the plant?
11
Is the facility compliant with all relevant OSHA regulations?
12
How many hours of safety training are provided per employee annually?
Min: 0
Target: 40
Max: 100
13
Have safety audits been conducted within the last year?
14
What measures are in place to ensure the use of personal protective equipment?
15
What lessons have been learned from past incidents?
16
Is process safety information readily accessible to all employees?
17
How often are risk assessments conducted (in months)?
Min: 1
Target: 12
Max: 24
18
Is safety integrated into daily operations and decision-making?
19
What methods are used to communicate safety information to employees?
20
What improvements have been made to the incident reporting process?
21
Is there visible management commitment to safety practices?
22
What is the current safety incident rate in the facility?
Min: 0
Target: 2
Max: 100
23
Are employees actively involved in safety programs and initiatives?
24
How is the effectiveness of safety training evaluated?
25
What improvements have been implemented as a result of safety audits?

FAQs

PSM audits should be conducted at least every three years, as required by OSHA. However, more frequent audits may be necessary for high-risk processes or following significant changes to equipment or procedures.

Key elements include process hazard analysis, operating procedures, training, mechanical integrity, management of change, incident investigation, emergency planning and response, and compliance audits.

The audit team should include process safety engineers, operations managers, maintenance personnel, and representatives from environmental health and safety departments. It's also beneficial to include third-party experts for an unbiased assessment.

The checklist helps identify gaps in process safety management systems, non-compliances with regulations, and areas for improvement in safety practices, allowing for targeted enhancements to reduce risks and prevent incidents.

Documentation to be reviewed includes process safety information, hazard analyses, operating procedures, training records, mechanical integrity programs, management of change records, incident investigation reports, and emergency response plans.

Benefits of Chemical Plant Process Safety Management (PSM) Audit Checklist

Ensures compliance with OSHA's Process Safety Management standard

Identifies and mitigates potential process hazards and risks

Improves the reliability and integrity of process equipment

Enhances emergency preparedness and response capabilities

Promotes a culture of continuous improvement in process safety