PSM Compliance Checklist
PSM Compliance Checklist
PSM Compliance Checklist
TASK/ITEM YES NO
This checklist was made available on OSHA’s website. Convergence Training did
not create the checklist (other than doing some reformatting), offers it for free
and does not sell it, and offers no guarantee that using this checklist will prevent
PSM-related infractions, hazards, incidents, damage, injuries, or fatalities.
Please check yes to confirm you have read and understood the statement above.
The checklist was accessed at OSHA’s website on May 2, 2014. You can find the
checklist at this link:
https://www.osha.gov/dte/grant_materials/fy09/sh-19479-
09/08_PSM_Auditing_Checklist.pdf
Comments/Notes:
Questions in the following section regard 1910.119(a), Application. n/a n/a
Does your workplace have a process which involves a chemical at or above the
specified threshold quantities listed in Appendix A to this section?
If your answer to this question is “yes,” your facility must comply with 1910.119.
(C) Retail facilities, oil or gas well drilling or servicing operations, or, normally
unoccupied remote facilities.
If your answer to this question is “yes,” your facility must comply with 1910.119.
NOTE: there are other interpretations that may exempt your facility from PSM
coverage. Click to see those other interpretations:
https://www.osha.gov/pls/oshaweb/owaquery.query_docs?src_doc_type=INTE
RPRETATIONS&src_anchor_name=1910.119&src_ex_doc_type=STANDARDS&src
_unique_file=1910_0119
Comments/Notes:
Questions in the following section regard 1910.119(b), Definitions. n/a n/a
Do you understand the definitions as presented in 29 CFR 1910.119(b),
including:
Atmospheric tank
Boiling point
Catastrophic release
Facility
Highly hazardous chemical
Hot work
Normally unoccupied remote facility
Process
Replacement in kind
Trade secret
Comments/Notes:
Questions in the following section regard 1910.119(c), Employee Participation. n/a n/a
Do you have a written plan of action regarding the implementation of the
employee participation?
Comments/Notes:
Have you consulted with employees and their representatives on the conduct
and development of process hazards analyses and on the development of the
other elements of process safety management in this standard?
Comments/Notes:
Have you provided to employees and their representatives access to process
hazard analyses and to all other information required to be developed under this
standard?
Comments/Notes:
Questions in the following section regard 1910.119(d), Written Process Safety n/a n/a
Information.
Does the written, compiled, and updated process safety information include
toxicity information?
Comments/Notes:
Does the written, compiled, and updated process safety information include
permissible exposure limits?
Comments/Notes:
Does the written, compiled, and updated process safety information include
physical data?
Comments/Notes:
Does the written, compiled, and updated process safety information include
reactivity data?
Comments/Notes:
Does the written, compiled, and updated process safety information include
corrosivity data?
Comments/Notes:
Does the written, compiled, and updated process safety information include
thermal and chemical stability data?
Comments/Notes:
Does the written, compiled, and updated process safety information include
hazardous effects of inadvertent mixing of different materials that could
foreseeably occur?
Comments/Notes:
The following questions relate to information pertaining to the technology of n/a n/a
the process.
Does the information concerning the technology of the process include at least:
Materials of construction
Piping and instrument diagrams (P&IDs)
Electrical classification
Relief system design and design basis
Ventilation system design
Design codes and standards employed
Material and energy balances for processes built after May 26, 1992
Safety systems (e.g., interlocks, detection or suppression systems)
Comments/Notes:
Has the employer documented the ways in which that equipment complies with
recognized generally accepted good engineering practices?
Comments/Notes:
For existing equipment designed and constructed in accordance
with codes, standards, or practices that are no longer in general
use, did the employer determine and document that the equipment is designed,
maintained, inspected, tested, and operates in a safe manner?
Comments/Notes:
Questions in the following section regard 1910.119(e), Process Hazard Analysis. n/a n/a
Have you performed an initial process hazard analysis
(hazard evaluation) on processes covered by this standard, that
is appropriate to the complexity of the process that identifies, evaluates, and
controls the hazards involved in the process?
Comments/Notes:
Have you used one or more of the following methodologies that are appropriate
to determine and evaluate the hazards of the process:
• What-If;
• What-If/Checklist;
• Hazard and Operability Study (HAZOP);
• Failure Mode and Effects Analysis (FMEA);
• Fault Tree Analysis; or
• An appropriate equivalent methodology
Comments/Notes:
Has the employer developed written operating limits that include steps to avoid
or correct deviation?
Comments/Notes:
Has the employer developed written operating limits that include safety and
health considerations, particularly the properties of, and hazards presented by,
the chemicals used in the process?
Comments/Notes:
Has the employer developed written operating limits that include safety and
health considerations, particularly the precautions necessary to prevent
exposure, including engineering controls, administrative controls, and personal
protective equipment?
Comments/Notes:
Has the employer developed written operating limits that include safety and
health considerations, particularly control measures to be taken if physical
contact or airborne exposure occurs?
Comments/Notes:
Has the employer developed written operating limits that include safety and
health considerations, particularly the quality control measures for raw
materials and control of hazardous chemical inventory levels?
Comments/Notes:
Has the employer developed written operating limits that include safety and
health considerations, particularly any special or unique hazards?
Comments/Notes:
Are operating procedures readily accessible to employees who work in or
maintain a process?
Comments/Notes:
Have those operating procedures been reviewed as often as necessary to assure
that they reflect current operating practice, including changes that result from
changes in process chemicals, technology, and equipment, and changes to
facilities?
Comments/Notes:
Has the employer annually certified that these operating procedures are current
and accurate?
Comments/Notes:
Has the employer developed and implemented safe work practices to provide
for the control of hazards during operations such as lockout/tagout/confined
space entry; opening process equipment or piping; and control over entrance
into a facility by maintenance, contractor, laboratory, or other support
personnel?
Comments/Notes:
Do these safe work practices apply to both employees and contractor
employees?
Comments/Notes:
Does the employer have operating procedures addressing special situations
involved with a covered process? For example, there may need to be procedures
to prevent forklift damage in a refrigerated warehouse with ammonia
refrigeration equipment.
Comments/Notes:
Questions in the following section regard 1910.119(g), Training. n/a n/a
Has the employer provided to each employee presently involved in operating a
process, and each employee before being involved in operating a newly assigned
process, initial training in an overview of the process and in the operating
procedures as specified in paragraph (f) of the standard?
Comments/Notes:
Does the training include emphasis on the specific safety and health hazards,
emergency operations including shutdown, and safe work practices applicable to
the employee's job tasks?
Comments/Notes:
Does training include discussion of human factors, such as excessive overtime
and fatigue, and process siting, such as safe distance of control rooms or
temporary maintenance facilities from processes using highly hazardous
chemicals?
Comments/Notes:
In cases when employees were already involved in operating a process before
May 26, 1992, has the employer certified in writing that the employee has the
required knowledge, skills, and abilities to safely carry out the duties and
responsibilities as specified in the operating procedures (instead of providing
initial training)?
Comments/Notes:
Has the employer provided refresher training at least every three years, and
more often if necessary?
Comments/Notes:
Has the employer consulted with the employees involved in operating the
process to determine the appropriate frequency of refresher training?
Comments/Notes:
Has the employer determined that each employee involved in operating a
process has received and understood the training?
Comments/Notes:
Has the employer documented that each employee has been trained and
understood training, including the identity of the employee, the date of training,
and the means used to verify that the employee understood the training?
Comments/Notes:
Questions in the following section regard 1910.119(h) Contractors Safety. n/a n/a
Here’s 1910.119(n):
Emergency planning and response. The employer shall establish and implement
an emergency action plan for the entire plant in accordance with the provisions
of 29 CFR 1910.38. In addition, the emergency action plan shall include
procedures for handling small releases. Employers covered under this standard
may also be subject to the hazardous waste and emergency response provisions
contained in 29 CFR 1910.120 (a), (p) and (q).
Here’s 1910.119(f)(4):
The employer shall develop and implement safe work practices to provide for
the control of hazards during operations such as lockout/tagout; confined space
entry; opening process equipment or piping; and control over entrance into a
facility by maintenance, contractor, laboratory, or other support personnel.
These safe work practices shall apply to employees and contractor employees.
Comments/Notes:
Did the employer periodically evaluate the performance of contract employers
in fulfilling their obligations as specified in 1910.119(h)(3)?
Here’s 1910.119(h)(3):
Contract employer responsibilities.
1910.119(h)(3)(i)
The contract employer shall assure that each contract employee is trained in the
work practices necessary to safely perform his/her job.
1910.119(h)(3)(ii)
The contract employer shall assure that each contract employee is instructed in
the known potential fire, explosion, or toxic release hazards related to his/her
job and the process, and the applicable provisions of the emergency action plan.
1910.119(h)(3)(iii)
The contract employer shall document that each contract employee has
received and understood the training required by this paragraph. The contract
employer shall prepare a record which contains the identity of the contract
employee, the date of training, and the means used to verify that the employee
understood the training.
1910.119(h)(3)(iv)
The contract employer shall assure that each contract employee follows the
safety rules of the facility including the safe work practices required by
paragraph (f)(4) of this section.
1910.119(h)(3)(v)
The contract employer shall advise the employer of any unique hazards
presented by the contract employer's work, or of any hazards found by the
contract employer's work.
Comments/Notes:
Did the employer maintain a contract employee injury and illness log related to
the contractor’s work in process areas?
Comments/Notes:
The following questions relate to the contract employer responsibilities. n/a n/a
Did the contract employer assure that each contract employee is trained in the
work practices necessary to safely perform his/her job?
Comments/Notes:
Has the contract employer assured that each contract employee is instructed in
the known potential fire, explosion, or toxic release hazards related to his/her
job and the process, and the applicable provisions of the emergency action plan?
Comments/Notes:
Did the contract employer document that each contractor employee has
received and understood the training required by this paragraph?
Comments/Notes:
Did the contract employer prepare a record which contains the identity of the
contract employee, the date of training, and the means used to verify that the
employee understood the training?
Comments/Notes:
Did the contract employer assure that each contract employee follows the safety
rules of the facility, including the safe work practices required by 1910.119(f)(4)?
Here’s 1910.119(f)(4): The employer shall develop and implement safe work
practices to provide for the control of hazards during operations such as
lockout/tagout; confined space entry; opening process equipment or piping; and
control over entrance into a facility by maintenance, contractor, laboratory, or
other support personnel. These safe work practices shall apply to employees and
contractor employees.
Comments/Notes:
Did the contract employer advise the employer of any unique hazards presented
by the contract employer’s work, or of any hazards found by the contract
employer’s work?
Comments/Notes:
Questions in the following section regard 1910.119(i), Pre-startup Safety n/a n/a
Review.
Did the employer perform a pre-startup safety review for new facilities and for
modified facilities when the modification is significant enough to require a
chance in the process safety information?
Comments/Notes:
Did the pre-startup safety review confirm that prior to the introduction of highly
hazardous chemicals to a process, construction and equipment is in accordance
with design specifications?
Comments/Notes:
Did the pre-startup safety review confirm that prior to the introduction of highly
hazardous chemicals to a process, safety, operating, maintenance, and
emergency procedures are in place and are adequate?
Comments/Notes:
(For new facilities), did the pre-startup safety review confirm that prior to the
introduction of highly hazardous chemicals to a process, a process hazard
analysis has been performed and recommendations have been resolved or
implemented before startup?
Comments/Notes:
(For modified facilities), did the pre-startup safety review confirm that prior to
the introduction of highly hazardous chemicals to a process, the modified facility
meets the requirements contained in management of change, paragraph (l).
Here’s 1910.119(l):
Management of change.
1910.119(l)(1)
The employer shall establish and implement written procedures to manage
changes (except for "replacements in kind") to process chemicals, technology,
equipment, and procedures; and, changes to facilities that affect a covered
process.
1910.119(l)(2)
The procedures shall assure that the following considerations are addressed
prior to any change:
1910.119(l)(2)(i)
The technical basis for the proposed change;
1910.119(l)(2)(ii)
Impact of change on safety and health;
1910.119(l)(2)(iii)
Modifications to operating procedures;
1910.119(l)(2)(iv)
Necessary time period for the change; and,
1910.119(l)(2)(v)
Authorization requirements for the proposed change.
1910.119(l)(3)
Employees involved in operating a process and maintenance and contract
employees whose job tasks will be affected by a change in the process shall be
informed of, and trained in, the change prior to start-up of the process or
affected part of the process.
1910.119(l)(4)
If a change covered by this paragraph results in a change in the process safety
information required by paragraph (d) of this section, such information shall be
updated accordingly.
1910.119(l)(5)
If a change covered by this paragraph results in a change in the operating
procedures or practices required by paragraph (f) of this section, such
procedures or practices shall be updated accordingly.
Comments/Notes:
Did the pre-startup safety review confirm that prior to the introduction of highly
hazardous chemicals to a process, training of each employee involved in
operating a process had been completed?
Comments/Notes:
The questions in the following section regard 1910.119(j), Mechanical Integrity n/a n/a
of Process Equipment.
Note: paragraphs (j)(2) through (j)(6) of this section apply to the following
process equipment: pressure vessels and storage tanks; piping systems
(including pipe components such as valves); relief and vent systems and devices;
emergency shutdown systems; controls (including monitoring devices and
sensors, alarms, and interlocks); and pumps.
Did the employer establish and implement written procedures to maintain the
on-going integrity of process equipment?
Comments/Notes:
Did the employer train each employee involved in maintaining the on-going
integrity of process equipment in an overview of that process and its hazards
and in the procedures applicable to the employee’s job tasks to assure that the
employee can perform the job tasks in a safe manner?
Comments/Notes:
Have inspections and tests been performed on process equipment?
Comments/Notes:
Did the inspections and testing procedures follow recognized and generally
acceptable good engineering practices?
Comments/Notes:
Is the frequency of inspections and tests of process equipment consistent with
applicable manufacturers' recommendations and good engineering practices?
Comments/Notes:
Do inspections and tests occur more than required by manufacturers’
recommendations and good engineering practices if determined necessary by
prior operating experience?
Comments/Notes:
Did the employer document each inspection and test that has been performed
on process equipment?
Comments/Notes:
Did the employer correct deficiencies in equipment that are outside acceptable
limits (defined by the process safety information in 1910.199(d) of this section)
before further use or in a safe and timely manner when necessary means are
taken to assure safe operation?
Comments/Notes:
In the construction of new plants and equipment, did the employer assure that
equipment as it is fabricated is suitable for the process application for which
they will be used?
Comments/Notes:
Have appropriate checks and inspections been performed to assure that
equipment is installed properly and is consistent with design specifications and
the manufacturer's instructions?
Comments/Notes:
Did the employer assure that maintenance materials, spare parts, and
equipment are suitable for the process application for which they will be used?
Comments/Notes:
The questions in the following section regard 1910.119(k), Hot Work Permits. n/a n/a
Does the employer issue hot work permits for hot work operations conducted
on or near a covered process?
Comments/Notes:
Do the hot work permits document that the fire prevention and protection
requirements in 29 CFR 1910.252(a) have been implemented prior to beginning
the hot work operations?
Check 1910.199(d):
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STAND
ARDS&p_id=9760
Comments/Notes:
When changes covered by 1910.199(d) resulted in a change in the operating
procedures or practices required by 1910.199(f), were such procedures or
practices updated accordingly?
Check 1910.199(f):
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STAND
ARDS&p_id=9760
Comments/Notes:
Questions in the following section regard 1910.119(m), Incident Investigations. n/a n/a
Has the employer investigated each incident which resulted in, or could
reasonably have resulted in, a catastrophic release of highly hazardous chemical
in the workplace?
Comments/Notes:
If the employer has investigated each incident, have the incident investigations
been initiated as promptly as possible, but not later than 48 hours following the
incident?
Comments/Notes:
Have incident investigation teams consisted of at least one person
knowledgeable in the process involved, including a contract employee if the
incident involved work of the contractor, and other persons with appropriate
knowledge and experience to thoroughly investigate and analyze the incident?
Comments/Notes:
Have reports been prepared at the conclusion of the investigation including:
Date of incident
Date the investigation began
A description of incident
Factors that contributed to the incident
Any recommendations resulting from the investigation
Corrective actions taken
Comments/Notes:
Did the employer establish a system to promptly address and resolve the
incident report findings and recommendations? Did the employer document the
resolutions and corrective actions?
Comments/Notes:
Have reports been reviewed with all affected personnel whose job tasks are
relevant to the incident findings, including contract employees where
applicable?
Comments/Notes:
Did the employer retain incident investigation reports for at least five years?
Comments/Notes:
Questions in the following section regard 1910.119(n), Emergency Planning n/a n/a
and Response Programs.
Note: Employers covered under this standard may also be subject to the
hazardous waste and emergency response provisions in 29 CFR 190.120(a), (p),
and (q).
Note: Nothing in this paragraph shall preclude the employer from requiring the
persons to whom the information is made available under paragraph (p)(1) of
this section to enter into confidentiality agreements not to disclose the
information as set forth in 29 CFR 1910.1200.
Note: This is subject to the rules and procedures set forth in 29 CFR
1910.1200(i)(1) through 1910.1200(i)(12).
Comments/Notes: