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Process safety audit checklist

Process safety audit checklist

Stay on top of high-risk operations with this checklist. It’s built for tracking compliance, finding issues early, and documenting your findings with precision.

Use this template
or download pdf
Process safety audit checklist

Stay on top of high-risk operations with this checklist. It’s built for tracking compliance, finding issues early, and documenting your findings with precision.

Use this template
or download pdf

About the Process safety audit checklist

From faulty pressure valves to outdated emergency plans, small oversights in high-risk industries can turn into big problems quickly. If you’re managing safety compliance in manufacturing, chemical processing, or any facility with hazardous materials, a process safety audit checklist is your frontline tool for keeping systems tight and teams accountable. This template helps you standardize audits, track safety protocols, and document findings with zero guesswork.

Key elements of the process safety audit checklist

A solid process safety audit checklist helps you move from reactive problem-solving to proactive risk management. Here’s what the template includes:

  1. PSM program overview: This section confirms whether a documented process safety management program exists and is up to date. It also checks if team roles are clearly assigned and if employees are trained on their specific responsibilities.
  2. Process hazard analysis (PHA) checkpoints: You use this part to document whether PHAs have been completed and reviewed, if action items are tracked, and whether safety systems identified in the analysis are actually working as intended.
  3. Mechanical integrity standards: Track how equipment is inspected, maintained, and tested. This section captures if procedures are being followed and whether issues are resolved in a timely manner.
  4. Operating procedure documentation: This part ensures that safe operating limits are clearly defined, procedures are current, and staff are trained. It’s where day-to-day operations meet long-term compliance.
  5. Emergency preparedness protocols: You’ll verify that emergency plans exist and are regularly tested. Your team should also know exactly what to do when something goes wrong.
  6. Review and update process: A good checklist reminds you to revisit each section periodically. Staying current keeps your audit process compliant and actionable.

Best practices for using the process safety audit checklist

Every facility has its own set of risks, equipment, and processes. Whether you’re auditing a chemical plant or a food processing line, you can tailor the checklist to ensure you’re asking the right questions.

Feel free to adjust the audit frequency and responsibility sections to reflect your internal workflow. Assign specific tasks to relevant roles within your team so follow-ups don’t fall through. For example, shift equipment-specific checks to your maintenance team while leaving procedural reviews to operations leads.

You can also modify the PHA section to focus on the types of hazards most relevant to your industry. If you’re handling flammable materials, add extra prompts for containment, ventilation, or fire suppression. If you work in logistics, shift the focus toward safe transport and chemical handling.

Another option is to include a custom scoring to rate findings based on severity. This helps you act faster where it matters most and organize your action plans more effectively.

Download Lumiform’s process safety audit checklist today

Bring consistency to your audits with this checklist template, no matter the size of your operation. Assign tasks, track issues, and maintain clean records that show exactly where your processes stand. It’s built to keep your findings clear so you can make organized follow-ups. With built-in logic, comment fields, and scoring options, it’s adaptable to fit even the most complex workflows.

Related categories

  • Operational excellence templates
  • Risk management and compliance templates
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  • Quality assurance templates
  • Risk assessment templates
Preview of the template
entity_item!!!
Page 1
Management Systems
Does the facility have a documented Process Safety Management (PSM) program?
Are roles and responsibilities for PSM clearly defined and communicated?
Is there a system in place to review and update the PSM program regularly?
Are employees trained on the PSM program and their specific responsibilities?
Are there procedures for management of change, incident investigation, and compliance audits?
Process Hazard Analysis
Has a comprehensive Process Hazard Analysis (PHA) been conducted?
Are PHAs reviewed and updated at the required intervals?
Are action items from PHAs tracked to completion?
Are employees involved in the PHA process?
Are safeguards and mitigation measures identified in the PHA in place and functioning?
Mechanical Integrity
Is there a documented Mechanical Integrity (MI) program in place?
Are MI inspections and testing conducted at the required frequencies?
Are inspection, testing, and maintenance records properly maintained?
Are personnel responsible for MI activities properly trained?
Are deficiencies identified during MI activities promptly addressed?
Operating Procedures
Are up-to-date operating procedures available for all covered processes?
Do the procedures clearly describe safe operating limits and steps?
Are procedures reviewed and updated at the required intervals?
Are employees trained on the operating procedures and their implementation?
Are there systems in place to ensure compliance with operating procedures?
Emergency Preparedness
Does the facility have a comprehensive Emergency Response Plan (ERP)?
Are emergency response equipment and systems regularly inspected and tested?
Are employees trained on the ERP and their roles and responsibilities?
Are emergency drills and exercises conducted at the required frequencies?
Are communication and notification procedures in the ERP up-to-date and effective?

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Related resources

Access a complete set of resources aimed at maximizing safety, quality, and operational excellence, including detailed guides, related templates, and real-world use cases.

Topic guides

Read in-depth guides covering key topics related to this article.

Safety audit: A comprehensive guide to proactive risk managementChemical hazards: A mandatory risk assesment guide (with examples for businesses & industries)Compliance audit mastery: A handbook for proactive businesses
See all topic guides

Template collections

See comprehensive collections of best practice templates related to this topic.

4 process safety management checklists for audits and reviews3 free risk identification templates for safety auditsTop 16 free safety audit checklist templates
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Use cases

Check out how the Lumiform software can be utilized for related use cases.

Safety audit softwareProcess safety management softwareRisk identification softwareOccupational health and safety software
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Other resources

Explore all the additional resources we offer to assist you in mastering this topic.

How to conduct a safety audit4 compliance audit key objectives5 Benefits of internal auditsHow to write a workplace safety policy

Frequently asked questions

What is the difference between a process safety audit and a general safety inspection?

A general safety inspection looks at day-to-day hazards like slips, trips, and PPE use. A process safety audit dives deeper into systems that prevent catastrophic incidents, such as chemical reactions, pressure systems, or flammable storage. It focuses more on systemic risk tied to your core processes.

Who should conduct a process safety audit?

Ideally, someone with technical expertise and no conflict of interest would conduct the audit. This might be an internal safety officer from another site or an external auditor. A fresh pair of eyes often spots what familiarity misses—plus, third-party auditors bring insights from other operations you might not have considered.

What are common red flags in process safety audits?

Missing documentation, expired training, or outdated hazard analyses are major red flags. Watch out too for gaps between written procedures and how work is actually done. A useful tactic is to interview operators and maintenance staff since they can find risks that aren’t always mentioned in the report.


This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.
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