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OSHA Process Safety Management (PSM) Audit Checklist

A comprehensive checklist for auditing Process Safety Management systems in chemical facilities to ensure compliance with OSHA's PSM standard and prevent major chemical accidents.

OSHA Process Safety Management (PSM) Audit Checklist

by: audit-now
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About This Checklist

Process Safety Management (PSM) is crucial for preventing catastrophic incidents in chemical facilities handling highly hazardous chemicals. This OSHA PSM Audit Checklist is an indispensable tool for ensuring compliance with OSHA's Process Safety Management standard (29 CFR 1910.119). By systematically evaluating key elements such as process hazard analysis, operating procedures, mechanical integrity, and management of change, this checklist helps identify gaps in PSM implementation, reduce risks, and maintain a robust safety culture in high-hazard chemical operations.

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Industry

Chemicals

Standard

OSHA PSM 1910.119

Workspaces

Chemical Processing Facilities

Occupations

Process Safety Engineer
PSM Coordinator
Chemical Process Engineer
Safety Manager
Operations Manager
1
Has a Process Hazard Analysis (PHA) been completed for all processes involving highly hazardous chemicals?
2
Are management of change procedures in place and being followed?
3
What percentage of mechanical integrity inspections are completed on schedule?
Min: 0
Target: 100
Max: 100
4
Describe the incident investigation process used in your facility.
5
Are employees trained on process safety management requirements?
6
Are the emergency shutdown systems for hazardous processes operational?
7
What percentage of required personal protective equipment (PPE) is available for employees?
Min: 0
Target: 100
Max: 100
8
How frequently is safety training conducted for employees?
9
Describe the maintenance procedures for safety equipment in the facility.
10
What date was the last inspection of safety equipment conducted?
11
Are all chemicals stored in compliance with OSHA regulations?
12
What is the average response time for chemical spill incidents (in minutes)?
Min: 0
Target: 10
Max: 60
13
Are Safety Data Sheets (SDS) readily available for all chemicals in the facility?
14
Describe the procedures for handling hazardous chemicals safely.
15
What date was the last chemical safety audit conducted?
16
Is there an implemented training program for process safety management?
17
What is the average attendance rate for process safety training sessions (in percentage)?
Min: 0
Target: 90
Max: 100
18
Are refresher training sessions conducted regularly for process safety?
19
Describe the process for reviewing and updating training materials.
20
What date was the last evaluation of the training program conducted?
21
Is process safety information complete and readily available for all processes?
22
How often are risk assessments conducted for hazardous processes (in months)?
Min: 1
Target: 12
Max: 24
23
Are there established procedures for reporting incidents and near misses?
24
Describe the process for reviewing and updating the emergency response plan.
25
What date was the last process safety management audit conducted?

FAQs

The primary purpose is to evaluate compliance with OSHA's Process Safety Management standard and identify areas for improvement in managing highly hazardous chemical processes.

OSHA requires that compliance audits be conducted at least every three years, but many companies choose to conduct them more frequently for better risk management.

The audit team should include individuals knowledgeable in PSM and the process being audited, such as process engineers, safety professionals, and operations personnel.

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

Audit results can identify areas needing improvement, leading to the development of corrective actions, updates to procedures, enhanced training programs, and overall strengthening of the PSM system.

Benefits of OSHA Process Safety Management (PSM) Audit Checklist

Ensures compliance with OSHA's PSM standard

Identifies gaps in process safety management systems

Helps prevent major chemical accidents and releases

Improves overall safety performance in high-hazard facilities

Facilitates continuous improvement in process safety practices