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Process safety review checklist

Process safety review checklist

Stay on top of hazards, procedures, and safety controls with a clear template made for thorough process safety reviews. It’s a reliable tool for guiding inspections and flagging risks.

Use this template
or download pdf
Process safety review checklist

Stay on top of hazards, procedures, and safety controls with a clear template made for thorough process safety reviews. It’s a reliable tool for guiding inspections and flagging risks.

Use this template
or download pdf

About the Process safety review checklist

One small oversight in a high-risk environment, like a blocked vent or missed alarm setting, can lead to a serious incident. If you’re managing operations in manufacturing, chemical processing, or any other safety-critical field, you know how vital thorough reviews are. This process safety review checklist helps you standardize assessments and keep critical details from being missed. It guides you through key steps of the review, from identifying hazards to tracking safety systems and assigning follow-ups.

Why you should use a process safety review checklist

Using a process safety review checklist template helps you cover the right bases without reinventing the wheel. Instead of starting from scratch each time, you can focus on what really matters—spotting hazards, improving safety measures, and avoiding costly incidents. It saves you time, keeps your team aligned, and reduces the risk of skipping something critical.

You can use this template to make reviews consistent across teams, so no matter who’s running the safety check, they address the same major points. This keeps everything consistent and audit-ready. Plus, it’s a great tool for training newer staff by walking them through a proven structure.

With this checklist, you create a clear, repeatable process that’s easy to document and track over time. After all, it’s your first line of defense against operational risks.

How to use the process safety review checklist effectively

Using the checklist helps keep your safety process systematic and thorough. Here’s how to make the most of it:

  1. Customize it to reflect your actual process. Before anything else, tweak the template to match your facility’s operations. Add relevant equipment, raw materials, and reaction types specific to your process. The template is fully editable in the app, so you can tailor it without needing a separate document.
  2. Fill it out during or just before your walkthrough. Use the checklist on-site—you don’t have to wait until after. Document details while you’re physically present to observe unit operations, check labeling, and inspect safety equipment. This keeps your notes accurate and based on real-time findings.
  3. Be specific and factual, not vague. When describing hazards or incidents, avoid general statements like “risk of explosion.” Instead, write what could cause it, such as: “overheating of exothermic reaction in Reactor B due to failed cooling jacket.” With this level of detail, others can act better on your insights.
  4. Assign clear actions after submission. Once the checklist is completed, identify what needs follow-up, such as repairs, retraining, or process changes, and communicate it to the right people. Use comments or tagging features in the app to document who’s responsible.
  5. Track trends over time. Don’t just file it away. Revisit checklists during audits or after incidents to spot patterns. You can use the app’s analytics to compare reviews and monitor improvements across cycles.

Download Lumiform’s process safety review checklist today

Instead of sorting through old spreadsheets or second-guessing about the last review, this template gives you a sharp, focused framework you can return to anytime. You’ll know exactly what to assess, what needs follow-up, and what’s already been handled—without wasting time chasing details. The layout is clean, intuitive, and built for real-world use. Get started with the template now and make it part of your routine!

Related categories

  • Health and safety management templates
  • Risk management and compliance templates
  • Chemical industry templates
  • Manufacturing templates
  • Quality assurance templates
  • Safety templates
Preview of the template
entity_item!!!
Page 1
Process Overview
Describe the overall process and key unit operations
List the major equipment involved (e.g. reactors, distillation columns, storage tanks)
Identify the raw materials, intermediates, and final products
Hazard Identification
Identify potential process safety hazards (e.g. flammability, toxicity, reactivity)
Describe any exothermic reactions or potential for runaway reactions
List any special handling requirements for hazardous materials
Process Safety Controls
Describe the safety instrumented systems (e.g. alarms, interlocks, shutdowns)
Explain the process for managing critical process safety equipment
Outline the process safety training program for operators
Process Safety Performance
Summarize the process safety incident history (e.g. accidents, near misses)
Describe any process safety performance indicators tracked
Identify any process safety improvement opportunities

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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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Frequently asked questions

What’s the best time to conduct a process safety review?

The most effective time is before a new campaign starts or after any major process change, like a new piece of equipment or updated procedures. You should also revisit the review after a near miss or incident. Doing it regularly, not just annually, helps you catch early warning signs that might otherwise be missed.

How detailed should process safety documentation be?

Be precise, not wordy, since the goal is to recording actionable insights. Rather than saying “adequate ventilation,” write “ventilation fan V-102 running at reduced capacity, so inspect for blockage.” This way, others can understand the issue quickly and respond correctly, even if you’re not around.

How do you make safety reviews more team-friendly?

Even if one person fills out the checklist, keep it visible and discuss it. Use Lumiform’s dashboard or a whiteboard to highlight key findings from each review. This turns it into a shared process. You can also tag team members to follow up on specific actions to keep momentum going.


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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