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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 with Lumiform

The Lumiform application helps frontline teams uphold internal standards effortlessly.
  • Customize this template or build your own
  • Fill out templates via mobile app
  • Assign and track corrective actions
  • Get reports and analyse your data
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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 with Lumiform

The Lumiform application helps frontline teams uphold internal standards effortlessly.
  • Customize this template or build your own
  • Fill out templates via mobile app
  • Assign and track corrective actions
  • Get reports and analyse your data
Prices start from ░░░ per month
Book a demo
Learn more
or Download template as PDF

This process safety audit checklist goes beyond standard safety inspections by focusing specifically on the critical systems managing hazardous chemicals and high-risk processes. You’ll evaluate all 14 PSM elements mandated by OSHA regulations, from process safety information documentation to compliance audit procedures.

When safety managers at chemical processing facilities implement structured audit protocols, they reduce the likelihood of regulatory citations and improve incident response times. This template provides a systematic framework to identify potential hazards, verify mechanical integrity of critical equipment, and ensure emergency response readiness—transforming complex safety requirements into actionable audit criteria for your high-risk operations.

Related categories

Preview of the template
Entity
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?

Frequently asked questions

What are the key components that must be included in a process safety audit checklist?

A process safety audit checklist must include the 14 PSM elements: employee participation, process safety information, hazard analysis, operating procedures, training, contractors, pre-startup safety reviews, mechanical integrity, hot work permits, management of change, incident investigation, emergency planning, compliance audits, and trade secrets. Each component requires specific documentation and verification processes.

Who should be part of the process safety audit team?

Your process safety audit team should include a mix of qualified personnel with different expertise: safety professionals familiar with PSM regulations, engineers who understand the technical aspects, operators with hands-on process knowledge, and at least one person independent of the audited process to maintain objectivity. This diverse team ensures comprehensive evaluation.

How can I ensure my process safety audit checklist meets current OSHA standards?

Keep your process safety audit template current by regularly reviewing OSHA’s PSM directive updates, subscribing to industry publications, consulting with certified safety professionals, and incorporating lessons from recent enforcement actions. The 2024 OSHA directive includes an 80-page list of questions for each PSM subsection that can guide your checklist development.

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.