OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist
This checklist covers OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist requirements under applicable federal and industry regulations.
- Industry: Manufacturing
- Frequency: Quarterly
- Estimated Time: 20-30 minutes
- Role: Process Safety Engineer
- Total Items: 20
- Compliance: OSHA 29 CFR 1910.119, EPA 40 CFR 68, RAGAGEP
Regulatory Documentation & Compliance Status
Verify current regulatory compliance status and required documentation is in order.
- Is current Process Safety Information (PSI) documented and accessible to employees?
- Are Material Safety Data Sheets current and available for all HHCs?
- Are P&IDs current, accurate, and available for all covered processes?
- Attach photo of process area P&ID posting location:
Process Hazard Analysis & Operating Procedures
Verify PHA currency and operating procedure compliance per 29 CFR 1910.119(e)(f).
- Has the Process Hazard Analysis been completed within required timeframes and action items tracked?
- Are all PHA recommendations resolved or documented with risk-based rationale?
- Are operating procedures current, accessible to operators, and reviewed annually?
- Attach photo of PHA action item tracking log:
Management of Change & Contractor Safety
Verify MOC compliance and contractor safety management per 29 CFR 1910.119(h)(l).
- Is the Management of Change procedure followed for all changes to process, equipment, or procedures?
- Are all contractors briefed on process hazards and emergency procedures before beginning work?
- PSM program overall compliance assessment:
- Attach photo of MOC documentation and contractor safety records:
Emergency Planning & Incident Investigation
Verify emergency planning and incident investigation program compliance.
- Is the emergency action plan current, exercised, and accessible to all employees?
- Are incident investigations completed within required timeframes with root causes identified?
- Days since last PSM compliance audit (365-day requirement):
- PSM Coordinator or EHS Manager certification of audit completion:
Corrective Actions & Inspector Sign-Off
Document all deficiencies and assign corrective actions. POPProbe auto-assigns these to team members, generates a signed PDF report instantly, and tracks compliance status across all locations. -> Start free, no credit card required
- List all deficiencies identified in this inspection:
- Overall compliance status?
- Corrective actions assigned to (name and department):
- Inspector digital signature and date:
Related Manufacturing Checklists
- OSHA 29 CFR 1910.119(e) Process Hazard Analysis (PHA) Checklist
- OSHA 29 CFR 1910.119(f) Operating Procedures Checklist
- OSHA 29 CFR 1910.119(g) PSM Training & Competency Checklist
- OSHA 29 CFR 1910.119(h) Contractor Safety Management Checklist
- OSHA 29 CFR 1910.119(i) Pre-Startup Safety Review (PSSR) Checklist
- OSHA 29 CFR 1910.119(j) Mechanical Integrity (MI) Program Checklist
- OSHA 29 CFR 1910.119(k) Hot Work Permit Verification Checklist
- OSHA 29 CFR 1910.119(l) Management of Change (MOC) Checklist
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Why Use This OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist?
This osha 29 cfr 1910.119 process safety information (psi) checklist helps manufacturing teams maintain compliance and operational excellence. Designed for process safety engineer professionals, this checklist covers 20 critical inspection points across 5 sections. Recommended frequency: quarterly.
Ensures compliance with OSHA 29 CFR 1910.119, EPA 40 CFR 68, RAGAGEP. Regulatory-aligned for audit readiness and inspection documentation.
Frequently Asked Questions
What should an OSHA 29 CFR 1910.119 Process Safety Information checklist include?
An OSHA 29 CFR 1910.119(d) PSI checklist must cover three categories of information. First, chemical hazard data for every highly hazardous chemical (HHC) in the process: toxicity, permissible exposure limits, physical data, reactivity, corrosivity, thermal and chemical stability, and hazardous effects of mixing (per 1910.119(d)(1)). Second, process technology information: block flow or simplified process flow diagrams, process chemistry, maximum intended inventory, upper and lower temperature, pressure, flow, and composition limits, and consequences of deviation (per 1910.119(d)(2)). Third, equipment information: materials of construction, P&IDs, electrical classification, relief system design and design basis, ventilation system design, codes used for design and construction, and, for existing equipment, a safe work practice program (per 1910.119(d)(3)). SDS sheets alone do not satisfy the HHC information requirement.
How often must Process Safety Information be reviewed and updated under OSHA PSM?
OSHA 29 CFR 1910.119 does not prescribe a standalone PSI review interval, but several requirements drive PSI updates. Operating procedures must be reviewed and certified as current annually per 1910.119(f)(3), which implicitly requires PSI to be accurate for that certification. The Process Hazard Analysis, which depends on current PSI, must be revalidated every five years per 1910.119(e)(6). Most critically, the Management of Change procedure under 1910.119(l) requires that PSI be updated before any change to technology, equipment, or procedures is implemented. OSHA National Emphasis Program inspectors treat outdated P&IDs, stale SDS data, and missing equipment data as PSI deficiencies even if no formal review cycle is violated. Best practice is quarterly verification of P&ID accuracy and annual comprehensive PSI document review.
What regulations apply to Process Safety Information compliance?
The primary regulation is OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous Chemicals, with PSI requirements at paragraph (d). For facilities above EPA threshold quantities, EPA 40 CFR Part 68 (Risk Management Plan) requires parallel documentation including a 5-year accident history and release scenario modeling - all anchored to accurate PSI. RAGAGEP (Recognized and Generally Accepted Good Engineering Practices) are incorporated by reference under 1910.119(d)(3)(iv) for equipment design documentation, making standards such as ASME Boiler and Pressure Vessel Code, ANSI/API 570, API 510, API 580, and NFPA 58 compliance evidence within the PSM/PSI framework. API RP 750 (Management of Process Hazards) and API RP 752/753 (Building Siting) further define industry good practice for facilities subject to OSHA PSM.
Who is responsible for maintaining Process Safety Information under OSHA PSM?
OSHA 29 CFR 1910.119(d) places the obligation on the employer, typically fulfilled by the Process Safety Manager or Process Safety Engineer assigned to the covered process. Practically, PSI maintenance is a multi-disciplinary responsibility: process engineers own technology information and P&IDs, chemical engineers or EHS staff own HHC hazard data, and mechanical integrity engineers own equipment documentation. In oil and gas and petrochemical facilities, inspection professionals holding API 510, API 570, or API 580 certifications are frequently assigned to maintain the equipment documentation element of PSI, including materials of construction, relief device design basis, and current inspection records. Contractors working on covered processes must be provided relevant PSI per 1910.119(h)(2)(i). OSHA holds the employer responsible regardless of which internal function maintains the records.
What are the penalties for incomplete or inaccurate Process Safety Information?
OSHA can cite PSI deficiencies under 29 CFR 1910.119(d) as serious, willful, or repeat violations. Serious violation penalties reach $16,550 per violation (29 CFR 1903.15, 2026); willful or repeat violations reach $165,514 per violation. OSHA's National Emphasis Program on PSM Covered Facilities (CPL 03-00-021) uses programmed inspections that begin with PSI verification, meaning incomplete PSI triggers a full 14-element PSM audit. In major incidents, missing or inaccurate PSI has been central to OSHA's willful findings: the 2005 Texas City BP refinery explosion ($21.4 million in proposed penalties) and subsequent enforcement actions repeatedly cited PSI deficiencies as root causes. Under the PSM standard, each element with missing information can be cited as a separate violation, compounding total penalty exposure significantly.
What is a OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist?
A OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist is a standardized inspection form used by process safety engineer to ensure consistent manufacturing operations. It contains 27 inspection points organized into 5 sections. FREE PDF - OSHA 29 CFR 1910.119 Process Safety Information (PSI) compliance checklist. Non-compliance can result in significant regulatory penalties and operational shutdowns.
How often should I use this manufacturing checklist?
This checklist is designed to be completed quarterly. Regular use ensures compliance with OSHA 29 CFR 1910.119 and EPA 40 CFR 68 and helps identify issues before they become problems.
Can I download this OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist as a PDF?
Yes, you can download this checklist as a FREE PDF for printing or offline use. The checklist includes 27 fields across 5 sections and typically takes 20-30 minutes to complete.
What compliance standards does this checklist cover?
This checklist helps ensure compliance with OSHA 29 CFR 1910.119, EPA 40 CFR 68, RAGAGEP. Following these standards protects your organization and ensures best practices.
How do I complete this manufacturing inspection checklist?
Begin by completing the header fields for Facility / Location, Inspection Date, Inspector Name, and Permit / Reference Number. Work through each of the 5 sections, marking items Yes or No as applicable. Add notes for any issues found. Finally, complete the footer fields and add your signature. The entire process takes approximately 20 to 30 minutes.
What are the key sections in this manufacturing checklist?
This manufacturing checklist is organized into 5 key sections: Regulatory Documentation & Compliance Status, Process Hazard Analysis & Operating Procedures, Management of Change & Contractor Safety, Emergency Planning & Incident Investigation, Corrective Actions & Inspector Sign-Off. Each section contains specific inspection points that process safety engineer must verify. The structured layout ensures nothing is missed during manufacturing inspections and makes the process efficient, typically taking 20-30 minutes to complete.
Who should use this OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist?
This checklist is primarily designed for process safety engineer working in manufacturing operations. However, it is also valuable for quality assurance teams, safety officers, compliance managers, and supervisors who need to verify that manufacturing standards are being met. Organizations of all sizes can benefit from using this OSHA 29 CFR 1910.119 Process Safety Information (PSI) Checklist to maintain consistency and accountability.