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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.

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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 with Lumiform

  • Customize this template or build your own
  • Fill out templates via mobile app
  • Get reports and analyse your data
Prices start from ░░░ per month
Book a demo
Learn more
or Download template as PDF

Your comprehensive process safety management checklist covers all 14 elements required by OSHA’s PSM standard. This template walks you through essential components including employee participation, process safety information, hazard analysis, and compliance audits. When preparing for regulatory inspections, you’ll have a systematic way to verify that all PSM requirements are properly implemented and documented.

The Chemical Safety Board reports that facilities with robust PSM programs experience significantly fewer catastrophic incidents involving hazardous chemicals. This checklist serves as both an implementation guide and audit tool, helping you identify gaps in your safety systems before they lead to dangerous conditions or compliance issues.

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Preview of the template
Entity
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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?

Frequently asked questions

What specific OSHA requirements does the process safety management checklist cover?

The checklist covers all 14 elements of OSHA’s PSM standard, including employee participation, process safety information, hazard analysis, operating procedures, training, mechanical integrity, management of change, incident investigation, emergency planning, and compliance audits. It follows the structure outlined in 29 CFR 1910.119 to ensure comprehensive compliance.

How often should I use the process safety management checklist?

You should use the checklist during initial PSM implementation, whenever significant process changes occur, and during required compliance audits (at least once every three years per OSHA requirements). Many facilities also conduct more frequent internal reviews using sections of the checklist to ensure ongoing compliance and identify potential issues before they become problems.

Can this checklist help me prepare for an OSHA PSM inspection?

Yes, this checklist is specifically designed to help you prepare for OSHA inspections by verifying your compliance with all 14 elements of the PSM standard. It provides a systematic approach to reviewing documentation, procedures, and practices that inspectors typically examine, helping you identify and address gaps before an official inspection occurs.

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.