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
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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.

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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?

Select compliance status.

To ensure adherence to regulatory requirements that protect workers from chemical hazards.
2
Is there adequate documentation for hazard analyses conducted?

Provide a brief description of the documentation.

Documentation is essential for verifying that hazard analyses are performed and reviewed.
3
How often are mechanical integrity inspections conducted?

Enter the frequency of inspections (in months).

Regular inspections are crucial for maintaining equipment safety and integrity.
Min: 1
Target: 12
Max: 12
4
Describe the procedures for management of change in the facility.

Provide detailed descriptions of the change management procedures.

Effective management of change is critical to maintaining safety and compliance.
5
Is emergency response training conducted regularly?

Indicate whether training is conducted regularly.

Regular training ensures readiness in case of an emergency involving hazardous materials.

6
Is the facility's chemical labeling in compliance with GHS standards?

Select the compliance status for GHS labeling.

Compliance with GHS labeling is essential for ensuring proper communication of hazards.
7
When was the last review of the emergency response plan conducted?

Provide the date of the last review.

Regular reviews ensure that the emergency response plan remains effective and current.
8
What is the frequency of safety procedure training for employees?

Enter the frequency of training (in months).

Frequent training helps to maintain a high level of safety awareness among employees.
Min: 1
Target: 6
Max: 12
9
Describe the procedures in place for incident reporting.

Provide a detailed description of the incident reporting procedures.

Effective incident reporting is critical for continuous improvement and safety enhancements.
10
Is all necessary safety equipment readily available and accessible?

Indicate whether safety equipment is available and accessible.

Availability of safety equipment is vital for ensuring worker safety during emergencies.

11
Has a Process Hazard Analysis been completed for all processes?

Select the completion status of the PHA.

Completing a PHA is essential for identifying and mitigating potential hazards.
12
What risk mitigation measures are implemented based on the PHA findings?

Provide a summary of the risk mitigation measures.

Documenting mitigation measures helps ensure that identified risks are managed effectively.
13
How many incidents related to chemical processes occurred in the last year?

Enter the number of incidents.

Tracking incident frequency helps identify trends and areas for improvement.
Min: 0
Target: 0
Max: 100
14
Summarize the findings from the latest safety audit.

Provide a detailed summary of the safety audit findings.

Audit findings provide insights into areas that need attention or improvement.
15
Have emergency response drills been conducted in the past year?

Indicate whether emergency drills have been conducted.

Regular drills ensure that employees are prepared for emergencies involving hazardous chemicals.

16
Are all chemical process control systems functioning as intended?

Select the functionality status of the control systems.

Ensuring control systems operate correctly is critical for safe and efficient chemical processing.
17
Are calibration records for instruments and control systems up to date?

Provide details on the status of calibration records.

Up-to-date calibration records are essential for maintaining accuracy and reliability of measurements.
18
How many control system failures have occurred in the past year?

Enter the number of control system failures.

Tracking failures helps identify trends and improve system reliability.
Min: 0
Target: 0
Max: 100
19
Describe the incident response procedures for control system failures.

Provide a detailed description of the incident response procedures.

Effective incident response procedures are crucial for minimizing risks associated with control system failures.
20
Have employees received training on the operation of control systems?

Indicate whether training on control systems has been conducted.

Training ensures that employees are knowledgeable about the control systems they work with.

21
Are Safety Data Sheets available and accessible for all hazardous chemicals?

Select the availability status of Safety Data Sheets.

Access to SDS is crucial for ensuring that employees have the necessary information to handle chemicals safely.
22
What training programs are in place for employees handling hazardous chemicals?

Provide details about the chemical training programs.

Training programs are essential for ensuring safe handling and awareness of hazards associated with chemicals.
23
How many chemical spills have occurred in the last year?

Enter the number of chemical spills.

Tracking spill incidents helps evaluate the effectiveness of safety protocols and response measures.
Min: 0
Target: 0
Max: 100
24
Describe the procedures for conducting chemical risk assessments.

Provide a comprehensive description of the risk assessment procedures.

Detailed procedures for risk assessments help ensure that potential hazards are identified and mitigated.
25
Is personal protective equipment readily available for all employees?

Indicate whether PPE is readily available.

Availability of PPE is essential for ensuring the safety of employees working with hazardous chemicals.

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

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