PSM Compliance Checklist
PSM Compliance Checklist
PSM Compliance Checklist
TASK/ITEM
This checklist was made available on OSHAs 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.
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NO
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Please check yes to confirm you have read and understood the statement above.
The checklist was accessed at OSHAs website on May 2, 2014. You can find the
checklist at this link:
https://www.osha.gov/dte/grant_materials/fy09/sh-1947909/08_PSM_Auditing_Checklist.pdf
Comments/Notes:
Questions in the following section regard 1910.119(a), Application.
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.
Check Appendix A here:
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STAND
ARDS&p_id=9761
Comments/Notes:
Does your workplace have a process which involves a Category 1 flammable gas
[as defined in 1910.1200(c)] or a flammable liquid with a flashpoint below 100
degrees F (37.8 degrees C), on site in one location, in a quantity of
10,000 pounds (4535.9 kg) or more, except:
(A) Hydrocarbon fuels used solely for workplace
consumption as a fuel (e.g., propane used for comfort
heating, gasoline for vehicle refueling), if such fuels are not a
part of a process containing another highly hazardous
chemical covered by this standard;
(B) Flammable liquids stored in atmospheric tanks or
transferred which are kept below their normal boiling point
without benefit of chilling or refrigeration.
(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.
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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.
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
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
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standard?
Comments/Notes:
Questions in the following section regard 1910.119(d), Written Process Safety
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
the process.
Does the information concerning the technology of the process include at least:
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Comments/Notes:
Does the information pertaining to the equipment in the process include:
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
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
See the link for more information about these methodologies:
https://www.osha.gov/Publications/osha3133.html
Comments/Notes:
Has the process hazard analysis addressed the hazards of the process?
Comments/Notes:
Has the process hazard analysis addressed the identification of any previous
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(5) years?
Comments/Notes:
Does the employer have process hazards analyses and updates or revalidations
for each process?
Comments/Notes:
Does the employer have the documented resolution of recommendations
described in paragraph (e)(5)?
Heres paragraph (e)(5):
The employer shall establish a system to promptly address the team's findings
and recommendations; assure that the recommendations are resolved in a
timely manner and that the resolution is documented; document what actions
are to be taken; complete actions as soon as possible; develop a written
schedule of when these actions are to be completed; communicate the actions
to operating, maintenance and other employees whose work assignments are in
the process and who may be affected by the recommendations or actions.
Comments/Notes:
The questions in the following section refer to 1910.119(f), Operating
Procedures.
Has the employer developed and implemented written operating procedures
that provide clear instructions for safely conducting activities involved in each
covered process consistent with the process safety information?
Comments/Notes:
Do those written operating procedures include steps for initial startup?
Comments/Notes:
Do those written operating procedures include steps for normal operations?
Comments/Notes:
Do those written operating procedures include steps for temporary operations?
Comments/Notes:
Do those written operating procedures include steps for emergency shutdown?
Comments/Notes:
Do those written operating procedures include steps for emergency operations?
Comments/Notes:
Do those written operating procedures include steps for normal shutdown?
Comments/Notes:
Do those written operating procedures include steps for startup following a
turnaround or after an emergency shutdown?
Comments/Notes:
Has the employer developed written operating limits that include the
consequences of deviation?
Comments/Notes:
Has the employer developed written operating limits that include steps to avoid
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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:
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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 contractors work in process areas?
Comments/Notes:
The following questions relate to the contract employer responsibilities.
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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
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Comments/Notes:
Do the procedures assure that authorization requirements for the proposed
change are addressed prior to any change?
Comments/Notes:
Have employees who are involved in operating a process and maintenance and
contract employees whose job tasks will be affected by a change in the process
been informed of, and trained in, the change prior to start-up of the process or
affected part of the process?
Comments/Notes:
When changes covered by 1910.199(l) resulted in a change in the process safety
information required by 1910.199(d), was such information updated
accordingly?
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.
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
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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
and Response Programs.
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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).
See 29 CFR 1910.120:
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standar
ds&p_id=9765
Comments/Notes:
Has the employer established and implemented an emergency action plan for
the entire plant in accordance with the provisions of 29 CFR 1910.38?
See 29 CFR 1910.38:
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STAND
ARDS&p_id=9726
Comments/Notes:
Does the emergency action place include procedures for handling small
releases?
Comments/Notes:
Questions in the following section regard 1910.119(o,) Compliance Audits.
Has the employer certified that they have evaluated compliance with the
provisions of this section at least every three years to verify that the procedures
and practices developed under the standard are adequate and are being
followed?
Comments/Notes:
Has the compliance audit been conducted by at least one person knowledgeable
in the process?
Has a report of the findings of the audit been developed?
Comments/Notes:
Did the employer promptly determine and document an appropriate response
to each of the findings of the compliance audit?
Comments/Notes:
Did the employer document that the deficiencies were corrected?
Comments/Notes:
Did the employer retain the two (2) most recent compliance audit reports?
Comments/Notes:
Questions in the following section regard 1910.119(p), Trade Secrets.
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.
See 29 CFR 190.1200:
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STAND
ARDS&p_id=10099
Without regard to the possible trade secret status of such information, has the
employer made all information necessary to comply with the section available,
to those persons responsible for compiling the process safety information
(required by paragraph (d) of this section)?
Comments/Notes:
Without regard to the possible trade secret status of such information, has the
employer made all information necessary to comply with the section available,
to those persons assisting in the development of the process hazard analysis
(required by paragraph (e) of this section)?
Comments/Notes:
Without regard to the possible trade secret status of such information, has the
employer made all information necessary to comply with the section available,
to those persons responsible for developing the operating procedures (required
by paragraph (f) of this section?
Comments/Notes:
Without regard to the possible trade secret status of such information, has the
employer made all information necessary to comply with the section available,
to those persons involved in incident investigations (required by paragraph (m)
of this section)?
Comments/Notes:
Without regard to the possible trade secret status of such information, has the
employer made all information necessary to comply with the section available,
to those persons involved in emergency planning and response (required by
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