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Process safety management checklist

Process safety management checklist

Document critical process safety steps with this template, from hazard analysis to emergency response. Whether you’re updating protocols or conducting routine checks, it keeps your systems safer.

Use this template
or download pdf
Process safety management checklist

Document critical process safety steps with this template, from hazard analysis to emergency response. Whether you’re updating protocols or conducting routine checks, it keeps your systems safer.

Use this template
or download pdf

About the Process safety management checklist

Process safety incidents like unexpected chemical reactions, equipment breakdowns, or employee missteps can spiral quickly and have a severe impact. If you’re managing safety in manufacturing, oil and gas, or chemical production, you’re working to keep people safe and operations smooth, day in and day out. You can use this process safety management checklist to standardize how your team tracks hazards, follows procedures, and keeps critical systems in check. It helps you flag risks before they turn into problems and keep your process safety strategy proactive instead of reactive.

Key elements of the process safety management checklist

You can create structure where it matters most with the checklist, from hazardous materials to procedures for preventing major incidents. Here’s how the template works for you:

  1. Hazard identification and risk analysis: This section guides you through spotting potential process hazards before they escalate. You can use it to log flammable substances, pressure systems, or operational steps with higher risk levels.
  2. Operating procedures and responsibilities: Clarifies what needs to be done, when, and by whom. It supports consistent execution, especially during maintenance or start-up activities.
  3. Training and competency tracking: Verifies that employees understand their roles and can handle them safely. This part is crucial for auditing and helps close gaps in knowledge or skills.
  4. Mechanical integrity checks Covers equipment inspections and routine maintenance schedules. These checkpoints keep your infrastructure reliable and reduce the chance of unexpected failures.
  5. Emergency planning and response: You use this to outline protocols for handling fires, leaks, or system shutdowns. A clear plan limits confusion and boosts reaction time.
  6. Incident investigation logs: Captures past events, root causes, and the corrective actions taken. This section is about continuous improvement and learning from what’s already happened.

Best practices for using the process safety management checklist

Here are some tips for using the checklist with intention and consistency.

Start by reviewing and updating your checklist regularly. Your processes, equipment, and team change over time, so the checklist should adapt to them. Set a routine for reviews, such as quarterly, and always revisit it after incidents or system updates.

Next, assign clear responsibilities. Each task in the checklist should have a designated person or role. This keeps accountability visible and helps avoid oversights, especially in fast-paced or high-risk environments.

Be specific when describing checklist items. Vague instructions lead to inconsistent inspections. Instead of “Check valve,” say “Inspect valve seal for visible wear or leaks.” Specifics make the difference between a glance and a meaningful inspection.

It’s crucial to turn insights into action. Look for patterns in your findings, use them to schedule preventative maintenance, and feed that data back into training sessions and safety briefings.

Make your safety processes thorough and efficient

Download this template to standardize your inspections and keep your team aligned with what really matters. Whether you’re managing daily site walk-throughs or reviewing safety protocols before a shift change, this template keeps everyone on the same page. You’ll work faster, stay more organized, and create a trail of accountability without overcomplicating your process.

Related categories

  • Health and safety management templates
  • Risk management and compliance templates
  • Chemical industry templates
  • Manufacturing templates
  • Risk assessment templates
  • Safety templates
Preview of the template
entity_item!!!
Page 1
Process Hazard Analysis
Have you conducted a thorough Process Hazard Analysis (PHA) for all processes?
Does the PHA identify all potential hazards and consequences of an uncontrolled release of hazardous chemicals or energy?
Are recommendations from the PHA promptly addressed and implemented?
Operating Procedures
Do you have clear, written operating procedures for each step of your processes?
Are the operating procedures updated regularly and communicated to all relevant personnel?
Do the procedures include safety and health considerations?
Training
Have all employees involved in operating processes received comprehensive training?
Is the training program evaluated and updated periodically?
Do you maintain training records for all employees?
Mechanical Integrity
Do you have a preventive maintenance program in place for all process equipment?
Are inspections and tests performed on process equipment at regular intervals?
Are maintenance, inspection, and testing records properly documented?
Management of Change
Do you have a formal Management of Change (MOC) process in place?
Does the MOC process include a review of potential safety and health impacts?
Are all MOC records maintained and readily available?
Incident Investigation
Do you have a system in place for investigating all incidents, including near-misses?
Are the root causes of incidents identified and corrective actions implemented?
Are incident investigation reports documented and shared with relevant personnel?
Emergency Planning and Response
Do you have a comprehensive emergency response plan in place?
Have all employees received training on the emergency response plan?
Are emergency response drills conducted regularly to test the plan's effectiveness?

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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.

Workplace hazards: Effective management techniquesChemical hazards: A mandatory risk assesment guide (with examples for businesses & industries)Hazard communication program: A guide for workplace safety
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Template collections

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

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Chemical hazards softwareJob safety analysis softwareProcess safety management softwareDynamic risk assessment app
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5 Types of workplace hazards10 reasons why workplace safety is importantHow to write a workplace safety policy4 benefits of safety management and how to communicate them

Frequently asked questions

What’s the biggest mistake teams make with process safety management?

A common issue is treating process safety like a one-time setup rather than an ongoing routine. More than having protocols in place, these should be part of daily habits. If you only revisit procedures during audits or after incidents, you’re already behind. Make check-ins, training, and updates a regular rhythm.

Who should be involved in creating or updating safety protocols?

Don’t leave it all to management. Involve frontline employees who actually work with the systems daily. They can catch blind spots and offer practical insight. Maintenance crews, shift supervisors, and even temporary contractors can highlight risks or shortcuts that formal documentation might miss.

What’s an effective way to track safety issues over time?

Use trend tracking to spot recurring problems. If valve failures keep coming up in reports or you see repeated notes about blocked exits, dig deeper. Create a system with Lumiform that flags repeat mentions of specific risks or equipment so you can take meaningful action based on data.


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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