From faulty pressure valves to outdated emergency plans, small oversights in high-risk industries can turn into big problems quickly. If you’re managing safety compliance in manufacturing, chemical processing, or any facility with hazardous materials, a process safety audit checklist is your frontline tool for keeping systems tight and teams accountable. This template helps you standardize audits, track safety protocols, and document findings with zero guesswork.
Key elements of the process safety audit checklist
A solid process safety audit checklist helps you move from reactive problem-solving to proactive risk management. Here’s what the template includes:
- PSM program overview: This section confirms whether a documented process safety management program exists and is up to date. It also checks if team roles are clearly assigned and if employees are trained on their specific responsibilities.
- Process hazard analysis (PHA) checkpoints: You use this part to document whether PHAs have been completed and reviewed, if action items are tracked, and whether safety systems identified in the analysis are actually working as intended.
- Mechanical integrity standards: Track how equipment is inspected, maintained, and tested. This section captures if procedures are being followed and whether issues are resolved in a timely manner.
- Operating procedure documentation: This part ensures that safe operating limits are clearly defined, procedures are current, and staff are trained. It’s where day-to-day operations meet long-term compliance.
- Emergency preparedness protocols: You’ll verify that emergency plans exist and are regularly tested. Your team should also know exactly what to do when something goes wrong.
- Review and update process: A good checklist reminds you to revisit each section periodically. Staying current keeps your audit process compliant and actionable.
Best practices for using the process safety audit checklist
Every facility has its own set of risks, equipment, and processes. Whether you’re auditing a chemical plant or a food processing line, you can tailor the checklist to ensure you’re asking the right questions.
Feel free to adjust the audit frequency and responsibility sections to reflect your internal workflow. Assign specific tasks to relevant roles within your team so follow-ups don’t fall through. For example, shift equipment-specific checks to your maintenance team while leaving procedural reviews to operations leads.
You can also modify the PHA section to focus on the types of hazards most relevant to your industry. If you’re handling flammable materials, add extra prompts for containment, ventilation, or fire suppression. If you work in logistics, shift the focus toward safe transport and chemical handling.
Another option is to include a custom scoring to rate findings based on severity. This helps you act faster where it matters most and organize your action plans more effectively.
Download Lumiform’s process safety audit checklist today
Bring consistency to your audits with this checklist template, no matter the size of your operation. Assign tasks, track issues, and maintain clean records that show exactly where your processes stand. It’s built to keep your findings clear so you can make organized follow-ups. With built-in logic, comment fields, and scoring options, it’s adaptable to fit even the most complex workflows.