Single logo
LoginSign Up

Chemical Process Safety Management (PSM) Audit Checklist

A comprehensive checklist for auditing Process Safety Management (PSM) programs in chemical facilities, ensuring compliance with OSHA standards and GHS guidelines, and addressing critical aspects of process safety to prevent major chemical incidents.

Chemical Process Safety Management (PSM) Audit Checklist

by: audit-now
4.6

Get Template

About This Checklist

The Chemical Process Safety Management (PSM) Audit Checklist is an indispensable tool for ensuring the safety and integrity of chemical processes in industrial settings. This comprehensive checklist aligns with OSHA's Process Safety Management standard and incorporates GHS principles. It addresses critical aspects of process safety, including hazard analysis, operating procedures, mechanical integrity, and emergency planning. By implementing this checklist, organizations can proactively identify and mitigate risks associated with highly hazardous chemicals, prevent catastrophic incidents, and maintain regulatory compliance. Regular PSM audits using this checklist help foster a culture of continuous improvement in process safety, ultimately safeguarding employees, the environment, and the surrounding community.

Learn more

Industry

Chemicals

Standard

GHS - Globally Harmonized System for Chemical Classification",ISO 9004 - Quality Management - Quality of an Organization"

Workspaces

refineries
Chemical Processing Facilities
Chemical Processing Facilities

Occupations

Process Safety Engineer
Chemical Plant Manager
PSM Coordinator
Operations Supervisor
EHS Manager
1
Is the facility in compliance with OSHA's Process Safety Management standards?
2
Is there adequate documentation for hazard analyses conducted?
3
How often are mechanical integrity inspections conducted?
Min: 1
Target: 12
Max: 12
4
Describe the procedures for management of change in the facility.
5
Is emergency response training conducted regularly?
6
Is the facility's chemical labeling in compliance with GHS standards?
7
When was the last review of the emergency response plan conducted?
8
What is the frequency of safety procedure training for employees?
Min: 1
Target: 6
Max: 12
9
Describe the procedures in place for incident reporting.
10
Is all necessary safety equipment readily available and accessible?
11
Has a Process Hazard Analysis been completed for all processes?
12
What risk mitigation measures are implemented based on the PHA findings?
13
How many incidents related to chemical processes occurred in the last year?
Min: 0
Target: 0
Max: 100
14
Summarize the findings from the latest safety audit.
15
Have emergency response drills been conducted in the past year?
16
Are all chemical process control systems functioning as intended?
17
Are calibration records for instruments and control systems up to date?
18
How many control system failures have occurred in the past year?
Min: 0
Target: 0
Max: 100
19
Describe the incident response procedures for control system failures.
20
Have employees received training on the operation of control systems?
21
Are Safety Data Sheets available and accessible for all hazardous chemicals?
22
What training programs are in place for employees handling hazardous chemicals?
23
How many chemical spills have occurred in the last year?
Min: 0
Target: 0
Max: 100
24
Describe the procedures for conducting chemical risk assessments.
25
Is personal protective equipment readily available for all employees?

FAQs

The checklist covers process safety information, process hazard analysis, operating procedures, training, mechanical integrity, management of change, pre-startup safety review, emergency planning and response, and compliance audits.

A comprehensive PSM audit should be conducted at least every three years, with more frequent reviews of specific elements as needed or required by regulations.

The PSM audit team should include process safety engineers, operations managers, maintenance supervisors, EHS specialists, and employees directly involved in the processes being audited.

The checklist ensures that hazard communication aspects of PSM align with GHS standards, including proper chemical classification, labeling, and safety data sheet management within process safety information.

After the audit, findings should be documented, corrective actions should be developed and implemented, and progress should be tracked. The results should be communicated to management and relevant employees, and used to update PSM programs as necessary.

Benefits of Chemical Process Safety Management (PSM) Audit Checklist

Ensures compliance with OSHA PSM standards and GHS guidelines

Identifies and mitigates potential process hazards

Improves the reliability and safety of chemical processes

Reduces the risk of catastrophic incidents and chemical releases

Enhances employee awareness and participation in process safety