Process Safety Management (PSM) Auditing

OSHA's Process Safety Management standard (29 CFR 1910.119) applies to facilities that handle highly hazardous chemicals above specified threshold quantities. PSM compliance is not optional — and the consequences of failure can be catastrophic, both in terms of human life and regulatory penalties. Our PSM audits examine all 14 elements of the PSM standard with particular focus on the elements that OSHA inspectors most commonly cite: Process Hazard Analysis (PHA), Mechanical Integrity, Management of Change (MOC), and Operating Procedures.

• Process Hazard Analysis (PHA): Is your PHA current (revalidated within the required 5-year cycle)? Was it conducted by a qualified team? Most critically, is there a documented system for tracking and closing PHA recommendations? • Mechanical Integrity: We review your inspection, testing, and preventive maintenance programs for critical process equipment including pressure vessels, storage tanks, piping systems, relief devices, and control systems. • Management of Change (MOC): One of the most commonly cited PSM elements. We verify that your MOC process is robust and that all recent changes have been properly assessed for safety impact before implementation. • Operating Procedures: Are your procedures accurate, certified annually, readily accessible to operators, and do they include emergency shutdown procedures? We verify through both document review and operator interviews. • Hot Work Permits: A frequent source of incidents. We evaluate your hot work permitting process and verify compliance with requirements for fire watch and pre-work hazard assessment.

OSHA requires that PSM compliance audits be conducted at least every three years by personnel knowledgeable in the process being audited. While internal audits satisfy this requirement, independent third-party audits provide significantly greater value. Our auditors bring fresh eyes and cross-industry experience. We've seen what works — and what fails — across multiple chemical facilities, giving us the perspective to identify gaps that internal teams may have normalized or overlooked.