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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?

Select 'Compliant' if PHA is complete; otherwise, select 'Non-Compliant'.

To ensure that all processes have been evaluated for potential hazards.
2
Are management of change procedures in place and being followed?

Indicate whether management of change procedures are in place.

To verify that changes in the process are managed to maintain safety.
3
What percentage of mechanical integrity inspections are completed on schedule?

Enter the percentage of completed inspections.

To ensure that equipment is regularly inspected and maintained.
Min: 0
Target: 100
Max: 100
4
Describe the incident investigation process used in your facility.

Provide a detailed description of the incident investigation process.

To assess the effectiveness of incident investigations in preventing future occurrences.
5
Are employees trained on process safety management requirements?

Select 'Compliant' if all employees are trained; otherwise, select 'Non-Compliant'.

To ensure that all employees are aware of safety procedures and regulations.
6
Are the emergency shutdown systems for hazardous processes operational?

Indicate whether the emergency shutdown systems are operational.

To ensure that emergency systems are functional in case of an incident.
7
What percentage of required personal protective equipment (PPE) is available for employees?

Enter the percentage of PPE available.

To verify that employees have access to necessary safety equipment.
Min: 0
Target: 100
Max: 100
8
How frequently is safety training conducted for employees?

Select the frequency of safety training.

To assess the regularity of safety training and its impact on safety culture.
9
Describe the maintenance procedures for safety equipment in the facility.

Provide a detailed description of maintenance procedures for safety equipment.

To evaluate the effectiveness of safety equipment maintenance protocols.
10
What date was the last inspection of safety equipment conducted?

Enter the date of the last safety equipment inspection.

To track when the last safety inspection occurred and ensure compliance.
11
Are all chemicals stored in compliance with OSHA regulations?

Select the compliance status of chemical storage.

To ensure that chemical storage practices meet regulatory standards for safety.
12
What is the average response time for chemical spill incidents (in minutes)?

Enter the average response time for chemical spills.

To evaluate the effectiveness of spill response protocols.
Min: 0
Target: 10
Max: 60
13
Are Safety Data Sheets (SDS) readily available for all chemicals in the facility?

Indicate whether SDS are available for all chemicals.

To ensure that necessary information regarding chemical hazards is accessible.
14
Describe the procedures for handling hazardous chemicals safely.

Provide a detailed description of chemical handling procedures.

To assess the effectiveness of chemical handling practices in maintaining safety.
15
What date was the last chemical safety audit conducted?

Enter the date of the last chemical safety audit.

To track the recency of chemical safety audits and ensure ongoing compliance.
16
Is there an implemented training program for process safety management?

Select the implementation status of the training program.

To verify that a structured training program exists for employees.
17
What is the average attendance rate for process safety training sessions (in percentage)?

Enter the average attendance rate for training sessions.

To assess employee engagement and participation in safety training.
Min: 0
Target: 90
Max: 100
18
Are refresher training sessions conducted regularly for process safety?

Indicate whether refresher training sessions are conducted.

To ensure that employees receive ongoing training to maintain safety standards.
19
Describe the process for reviewing and updating training materials.

Provide a detailed description of the training materials review process.

To evaluate how frequently and effectively training materials are revised.
20
What date was the last evaluation of the training program conducted?

Enter the date of the last training program evaluation.

To track the recency of training evaluations and ensure effectiveness.
21
Is process safety information complete and readily available for all processes?

Select the completeness status of the process safety information.

To ensure that all necessary information about processes is accessible for safety assessments.
22
How often are risk assessments conducted for hazardous processes (in months)?

Enter the frequency of risk assessments in months.

To evaluate the regularity of risk assessments and ensure ongoing safety evaluations.
Min: 1
Target: 12
Max: 24
23
Are there established procedures for reporting incidents and near misses?

Indicate whether incident reporting procedures are established.

To verify that there are clear procedures in place to report safety incidents.
24
Describe the process for reviewing and updating the emergency response plan.

Provide a detailed description of the emergency response plan review process.

To assess the effectiveness of the emergency response plan and its updates.
25
What date was the last process safety management audit conducted?

Enter the date of the last process safety audit.

To track the recency of audits and ensure compliance with safety standards.

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