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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?

Select the compliance status of the hazard analysis process.

To ensure that hazards are properly identified and assessed as part of the PSM requirements.
2
Are mechanical integrity procedures implemented and followed?

Indicate whether mechanical integrity procedures are in place.

To verify that the equipment maintenance is in accordance with safety standards.
3
How often is emergency planning training conducted (in months)?

Enter the frequency of emergency planning training.

To ensure that staff are regularly trained in emergency response procedures.
Min: 1
Target: 6
Max: 12
4
Are incident prevention measures documented and reviewed regularly?

Select the status of incident prevention measures.

To confirm that the organization has proactive measures to prevent incidents.
5
What feedback have you received regarding the safety culture in the plant?

Provide any relevant feedback about the safety culture.

To gather insights on the perception of safety culture among employees.
6
Are the operating procedures reviewed and updated regularly?

Select the review status of operating procedures.

To ensure that procedures are current and reflect best practices for safety.
7
Describe the process for investigating incidents when they occur.

Provide a detailed description of the incident investigation process.

To evaluate the effectiveness of the incident investigation process.
8
What is the percentage of personnel that have completed PSM training?

Enter the percentage of personnel who have completed PSM training.

To assess the level of training compliance among employees.
Min: 0
Target: 100
Max: 100
9
Is there an emergency response team available at all times?

Indicate whether an emergency response team is available.

To ensure readiness in case of an emergency situation.
10
What suggestions do you have for improving safety in the plant?

Provide any safety improvement suggestions.

To encourage feedback and suggestions for enhancing safety measures.
11
Is the facility compliant with all relevant OSHA regulations?

Select the compliance status with OSHA regulations.

To ensure that the facility meets regulatory requirements for safety.
12
How many hours of safety training are provided per employee annually?

Enter the number of safety training hours provided per employee.

To evaluate the commitment to employee training in safety practices.
Min: 0
Target: 40
Max: 100
13
Have safety audits been conducted within the last year?

Indicate whether safety audits have been conducted.

To ensure regular evaluations of safety practices are taking place.
14
What measures are in place to ensure the use of personal protective equipment?

Describe the measures in place for PPE usage.

To assess the effectiveness of PPE usage and enforcement.
15
What lessons have been learned from past incidents?

Provide details on lessons learned from incidents.

To gather insights for improving future safety practices and prevent recurrence.
16
Is process safety information readily accessible to all employees?

Select the availability status of process safety information.

To ensure that employees have access to critical safety information necessary for safe operations.
17
How often are risk assessments conducted (in months)?

Enter the frequency of risk assessments conducted.

To determine the frequency of risk assessments, which is critical for ongoing safety management.
Min: 1
Target: 12
Max: 24
18
Is safety integrated into daily operations and decision-making?

Indicate if safety is integrated into daily operations.

To assess whether safety considerations are part of everyday operational practices.
19
What methods are used to communicate safety information to employees?

Describe the communication methods for safety information.

To evaluate how effectively safety information is communicated within the organization.
20
What improvements have been made to the incident reporting process?

Provide details on improvements to the incident reporting process.

To review enhancements in the process that may lead to better incident management.
21
Is there visible management commitment to safety practices?

Select the status of management commitment to safety.

To assess the level of leadership support for safety initiatives within the organization.
22
What is the current safety incident rate in the facility?

Enter the current safety incident rate.

To evaluate the effectiveness of safety measures based on incident occurrences.
Min: 0
Target: 2
Max: 100
23
Are employees actively involved in safety programs and initiatives?

Indicate whether employees are involved in safety programs.

To ensure that employees take part in and contribute to safety efforts.
24
How is the effectiveness of safety training evaluated?

Describe the evaluation methods for safety training.

To determine the methods used to assess the impact of safety training programs.
25
What improvements have been implemented as a result of safety audits?

Provide details on improvements made from safety audits.

To track changes made based on audit findings to enhance safety.

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