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Process safety management plan template

Process safety management plan template

Get an editable template to build your process safety management plan from the ground up. It covers key areas like hazard analysis and emergency response with clearly organized sections.

Use this template
or download pdf
Process safety management plan template

Get an editable template to build your process safety management plan from the ground up. It covers key areas like hazard analysis and emergency response with clearly organized sections.

Use this template
or download pdf

About the Process safety management plan template

One missed step, and your whole process is at risk. In industries like manufacturing, chemicals, or logistics, where precision is non-negotiable, it’s critical to have a documented system. This process safety management plan template helps you record, track, and review the procedures that keep everything running safely. You can use this template to outline each stage of your safety program, from hazard identification to emergency response.

Streamline your safety management workflow

This process safety management plan breaks down complex safety protocols into bite-sized, actionable sections, so you don’t have to start from zero every time. This means fewer errors and more time actually managing safety rather than dealing with paperwork.

You can use the template to align your team around clear expectations. Everyone sees the same structure, follows the same process, and knows exactly where to find or add information. This improves training, audits, and day-to-day coordination.

It’s organized by components like hazard analysis, mechanical integrity, and emergency response. This allows you to spot gaps as well as assign responsibilities, and track progress. Make the most of the template by using it as a dynamic document during planning and inspections.

Getting the most out of your process safety management plan template

A process safety management plan is how you keep people safe, operations running smoothly, and surprises to a minimum. This editable template gives you a practical framework you can customize, fill out, and add to your daily workflow:

  1. Start by customizing the sections. First, tailor the template to fit your specific operation. Add details about your process, hazardous materials, equipment types, and any local compliance requirements.
  2. Use the template as an up-to-date document. As you walk through your process, edit fields in real time, especially during planning meetings, audits, or shift reviews. The goal is to keep information relevant and trustworthy.
  3. Train your team using the actual template. Instead of using slides or separate documents, guide people through this template during onboarding or refresher training. By seeing exactly how things are documented, they can understand how to act, where to look, and what to report.
  4. Document actions and incidents directly. When incidents or near-misses happen, log the details into the appropriate sections, like incident investigation or corrective action. This keeps everything connected in one place, making follow-up smoother and more transparent.
  5. Use analytics to spot trends. You can view your dashboard and data analytics at Lumiform. This lets you analyze recurring risks, overdue tasks, or equipment issues without digging through old reports.

Start using Lumiform’s process safety management plan template today

Download the template from Lumiform and make your operations more precise and efficient. You’ll be able to log crucial details, assign responsibilities, and track tasks all in one place, without losing time looking through scattered notes or clunky spreadsheets. With sections tailored to each phase of safety management, it gives you clarity and consistency.

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Preview of the template
entity_item!!!
Page 1
Process Description
Describe the chemical process or operation
Identify the hazardous materials and quantities involved
Outline the operating parameters and limits
Process Hazard Analysis
Identify potential hazards and risks associated with the process
Evaluate the consequences of process deviations or failures
Conduct a hazard and operability (HAZOP) study
Operating Procedures
Develop clear and detailed operating procedures
Ensure procedures address safety critical steps
Implement a management of change process
Training and Competency
Provide comprehensive training for all personnel
Assess and document employee competency levels
Maintain training records and refresh as needed
Mechanical Integrity
Establish a preventive maintenance program
Implement inspection and testing procedures
Document equipment design, installation, and maintenance
Emergency Planning and Response
Develop emergency response plans and procedures
Ensure access to appropriate emergency equipment
Conduct regular emergency drills and exercises
Incident Investigation and Corrective Action
Establish a system for reporting and investigating incidents
Identify root causes and implement corrective actions
Share learnings and best practices across the organization
Compliance and Documentation
Ensure compliance with all relevant regulations and standards
Maintain comprehensive records and documentation
Conduct regular audits and reviews of the process safety program

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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.

Chemical hazards: A mandatory risk assesment guide (with examples for businesses & industries)Hazard communication program: A guide for workplace safetyHazard identification: A guide for safer workplaces
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Template collections

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

4 process safety management checklists for audits and reviews5 hazard identification forms for workplace safety6 free hazard report form templates
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Use cases

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

Chemical hazards softwareConduct inspections with Lumiform's customizable workflow softwareJob safety analysis softwareProcess safety management software
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Other resources

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

10 reasons why workplace safety is important4 steps of a job safety analysis (JSA)4 ways that workplace safety increases worker productivityHow to write a workplace safety policy

Frequently asked questions

How detailed should the hazard analysis section really be?

The hazard analysis should be clear and detailed. Don’t only list down “flammable materials” or “high pressure.” Break it down and include what material, where it’s stored, exact pressure thresholds, and potential ignition sources nearby. Think through scenarios like “what happens if X fails?” Then combine it with photos or diagrams if possible.

How do you know if your process safety training is working?

Ask your team questions outside of formal training. For example, “What’s the first step if this valve fails?” or “Where’s the emergency shutoff?” You’ll get a clearer picture of what actually stuck. You can also run unannounced drills and use their responses as informal assessments, which is more useful than only reviewing training attendance.

Should contractors follow the same process safety procedures?

Absolutely. Include contractors in safety briefings, give them the same access to the plan, and check their understanding before they start work. If they’re operating under different assumptions, If it can lead to significant risks.


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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