Process Safety Management (PSM) Audit Checklist [FREE PDF]

Process Safety Management audits are required under OSHA 29 CFR 1910.119 for facilities handling highly hazardous chemicals above threshold quantities, with compliance audits mandated at least every three years. The PSM standard's 14 elements form the framework for preventing catastrophic releases and must be systematically evaluated against documented procedures, training records, and physical conditions. This audit checklist provides a structured evaluation tool aligned with OSHA 1910.119, API

  • Industry: Refining
  • Frequency: Annually
  • Estimated Time: 4-8 hours
  • Role: Process Safety Engineer
  • Total Items: 43
  • Compliance: OSHA 29 CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals, API RP 750 Management of Process Hazards, EPA 40 CFR Part 68 Chemical Accident Prevention Provisions (RMP), NFPA 30 Flammable and Combustible Liquids Code, BSEE 30 CFR 250 Oil and Gas and Sulphur Operations on the OCS

Process Safety Information (PSI)

Verify that complete, accurate, and up-to-date process safety information is documented and accessible to employees and contractors involved in PSM-covered processes.

  • Is written process safety information compiled and available for all covered processes prior to conducting PHAs?
  • Do Safety Data Sheets (SDS) for all highly hazardous chemicals meet OSHA 1910.119(d)(1) requirements including toxicity, permissible exposure limits, and reactivity data?
  • Are P&IDs current, field-verified, and reflective of as-built conditions for all covered process equipment?
  • Are equipment design codes, specifications, and relief system design basis documents available and current?
  • Are maximum intended inventories, temperature and pressure limits, and chemical concentration limits documented for each covered process?

Process Hazard Analysis (PHA)

Evaluate the adequacy, currency, and implementation of process hazard analyses for all PSM-covered processes.

  • Has an initial PHA been completed for all PSM-covered process units using an appropriate methodology (HAZOP, What-If, FMEA, or equivalent)?
  • Have all PHAs been updated and revalidated at least every five years since the initial PHA?
  • Are PHA recommendations tracked to completion with documented resolution and management of change records where applicable?
  • Does the PHA consider previous incidents with catastrophic potential and the facility's incident history?
  • Have PHA results been communicated to all affected operating and maintenance employees?
  • Are PHA records, including team composition, methodology, findings, and recommendations, retained for the life of the process?

Operating Procedures

Assess the adequacy, currency, and accessibility of written operating procedures for all phases of covered process operations.

  • Are written operating procedures developed and implemented for all PSM-covered process operating phases including normal, startup, shutdown, and emergency operations?
  • Are operating procedures certified as accurate and current at least annually?
  • Are procedures accessible to employees working in or on the covered process?
  • Do operating procedures include consequences of deviation, steps to avoid deviation, and safety and health considerations?
  • Are safe work practices (hot work, confined space, LOTO, line breaking) documented and integrated with operating procedures?

Training and Competency

Verify that initial and refresher training programs are in place, effective, and documented for all employees involved in PSM-covered processes.

  • Have all employees operating PSM-covered processes received initial training covering overview of the process, safety and health hazards, emergency operations, and safe work practices?
  • Is refresher training provided to operators at minimum every three years or more frequently if required?
  • Are training records maintained documenting identity of employee, date of training, and means used to verify understanding?
  • Do contractors working on or adjacent to covered processes receive appropriate PSM hazard information and safety rules?
  • Are operators evaluated for competency through knowledge testing or skills demonstration following training?

Mechanical Integrity

Assess the facility's mechanical integrity program for PSM-covered equipment including inspection and testing, maintenance procedures, quality assurance, and deficiency correction.

  • Is a written mechanical integrity program established and implemented for all covered equipment categories including pressure vessels, piping, relief devices, emergency shutdown systems, controls, and pumps?
  • Are inspection and testing frequencies consistent with applicable manufacturer recommendations and good engineering practice standards?
  • Are inspection and test records documenting date, equipment inspected, inspector name, serial number, description, and results maintained and available?
  • Are equipment deficiencies identified during MI inspections corrected before further use or in a safe and timely manner when necessary safeguards are in place?
  • Does the quality assurance program ensure that equipment, spare parts, and materials meet design specifications and are suitable for the process application?
  • Are pressure relief device inspection, testing, and maintenance records current and compliant with API RP 520 and API RP 576 requirements?

Management of Change (MOC)

Evaluate the facility's management of change program to ensure process changes are properly reviewed, approved, documented, and communicated before implementation.

  • Is a written management of change procedure established that addresses technical basis for change, impact on safety and health, modifications to operating procedures, time period for change, and authorization requirements?
  • Is MOC documentation reviewed to confirm that affected operating and maintenance personnel and contractors were trained on changes prior to startup?
  • Are process safety information documents (P&IDs, SOPs, equipment lists) updated to reflect all completed changes before process restart?
  • Does the MOC program clearly distinguish between changes and replacements-in-kind to prevent improper bypass of MOC review?
  • Are temporary changes managed through the MOC process with defined expiration dates and requirements for extension or permanent change?

Incident Investigation

Assess the facility's program for investigating process safety incidents, near-misses, and catastrophic release precursor events to identify root causes and implement systemic corrective actions.

  • Is an incident investigation initiated within 48 hours for all incidents that resulted in or could reasonably have resulted in a catastrophic release?
  • Do incident investigation teams include at least one person knowledgeable in the process involved and a contract employee representative if contractor work is involved?
  • Do written investigation reports include date of incident, date investigation began, description, factors contributing to incident, and recommendations?
  • Are incident investigation recommendations resolved and tracked to completion with documented management responses?
  • Are incident investigation reports retained for a minimum of five years and shared with affected employees?

Emergency Planning and Response

Verify that emergency action plans and response procedures for covered processes are documented, exercised, and integrated with community emergency response capabilities.

  • Is an emergency action plan established and implemented for all PSM-covered processes in compliance with OSHA 29 CFR 1910.38?
  • Does the emergency response plan address coordination with local emergency response agencies (fire department, LEPC, HazMat team)?
  • Are emergency response drills or tabletop exercises conducted and documented at a frequency consistent with the emergency plan?
  • Are emergency shutdown systems tested and verified functional at required intervals, with test records maintained?
  • Are personal protective equipment and emergency response equipment (supplied air, fire suppression, spill containment) inventoried, inspected, and ready for immediate use?
  • Provide observations and summary of findings for the emergency planning and response element review?

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Why Use This Process Safety Management (PSM) Audit Checklist [FREE PDF]?

This process safety management (psm) audit checklist [free pdf] helps refining teams maintain compliance and operational excellence. Designed for process safety engineer professionals, this checklist covers 43 critical inspection points across 8 sections. Recommended frequency: annually.

Ensures compliance with OSHA 29 CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals, API RP 750 Management of Process Hazards, EPA 40 CFR Part 68 Chemical Accident Prevention Provisions (RMP), NFPA 30 Flammable and Combustible Liquids Code, BSEE 30 CFR 250 Oil and Gas and Sulphur Operations on the OCS. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Process Safety Management (PSM) Audit Checklist [FREE PDF] cover?

This checklist covers 43 inspection items across 8 sections: Process Safety Information (PSI), Process Hazard Analysis (PHA), Operating Procedures, Training and Competency, Mechanical Integrity, Management of Change (MOC), Incident Investigation, Emergency Planning and Response. It is designed for refining operations and compliance.

How often should this checklist be completed?

This checklist should be completed annually. Each completion takes approximately 4-8 hours.

Who should use this Process Safety Management (PSM) Audit Checklist [FREE PDF]?

This checklist is designed for Process Safety Engineer professionals in the refining industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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