Perform Process Safety Management Audit using eAuditor
A Process Safety Management Audit (PSM Audit) is a systematic evaluation of how an organization implements and complies with process safety standards designed to prevent incidents involving hazardous chemicals and processes. It is based on frameworks such as OSHA 29 CFR 1910.119 (in the U.S.) or equivalent international standards.
The purpose of a PSM Audit is to verify that an organization has robust systems in place to identify, evaluate, and control risks associated with chemical processes that could lead to fires, explosions, toxic releases, or other catastrophic events.
Performing a Process Safety Management (PSM) Audit using eAuditor ensures a highly structured and detailed evaluation of all safety-critical systems involved in handling, storing, or processing hazardous chemicals. The goal is not only to comply with OSHA’s 14 PSM elements (or equivalent international standards like CCPS or ISO) but also to proactively identify, control, and eliminate risks that could lead to catastrophic incidents such as fires, explosions, or toxic releases. By leveraging eAuditor, the audit transforms into a live, interactive, and data-driven process with seamless integration of digital checklists, evidence capture, corrective action management, and analytics.
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Importance of PSM Audit with eAuditor
A PSM Audit helps organizations:
- Validate compliance with regulatory frameworks (e.g., OSHA 1910.119, EU Seveso Directive).
- Ensure systematic hazard identification and risk control at every stage of operations.
- Provide real-time visibility into site safety conditions for management and regulators.
- Establish a digital trail of accountability, where findings, approvals, and CAPAs are logged transparently.
- Foster a safety-first culture by engaging operators, contractors, and leadership in proactive safety practices.
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Expanded Elements of PSM Audit in eAuditor
2.1 Employee Participation
- Verify if employees are actively involved in hazard reviews, safety meetings, and training sessions.
- Capture digital signatures, photos of participation logs, and staff feedback within the app.
2.2 Process Safety Information (PSI)
- Audit the completeness of chemical data (toxicity, flammability, reactivity).
- Attach Material Safety Data Sheets (MSDS), equipment drawings, and pressure vessel certifications.
2.3 Process Hazard Analysis (PHA)
- Conduct HAZOP, What-If, or FMEA reviews digitally.
- Record all findings, assign risk ratings, and initiate CAPAs for unresolved hazards.
2.4 Operating Procedures
- Verify whether SOPs are documented, updated, accessible, and language-appropriate.
- Embed SOPs directly in eAuditor for staff to review during audits.
2.5 Training and Competency
- Cross-check training records, refresher sessions, and operator competency tests.
- Document training effectiveness with digital assessments.
2.6 Contractor Safety Management
- Evaluate contractor compliance with Permit to Work (PTW), induction, and PPE requirements.
- Upload permits, certificates, and check contractor risk controls.
2.7 Pre-Startup Safety Reviews (PSSR)
- Ensure all safety-critical checks are conducted before starting new or modified processes.
- Track approvals with timestamps and assign responsibility for unresolved issues.
2.8 Mechanical Integrity
- Review the inspection, testing, and preventive maintenance of equipment like boilers, tanks, valves, and alarms.
- Capture condition photos, vibration analysis reports, or calibration records.
2.9 Hot Work Permit Control
- Audit that all hot work activities (welding, cutting, grinding) have proper permits.
- Check that gas monitoring and fire watch procedures are followed.
2.10 Management of Change (MOC)
- Ensure every change (equipment, material, process) goes through formal review.
- Verify if risk assessments, approvals, and employee training were completed before implementation.
2.11 Incident Investigation
- Log incidents and near-misses in real time with supporting multimedia evidence.
- Perform Root Cause Analysis (RCA) and assign CAPAs directly within eAuditor.
2.12 Emergency Planning & Response
- Verify emergency drills, muster point checks, and evacuation route signage.
- Capture video or photo evidence of drills to prove preparedness.
2.13 Compliance Audit Records
- Track progress of past audit recommendations and measure closure rates.
- Store findings in a centralized database for retrieval during external inspections.
2.14 Documentation and Trade Secrets
- Ensure sensitive documents are accessible to authorized personnel only.
- Attach manuals, licenses, and safety management records securely in-app.
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End-to-End Workflow in eAuditor
3.1 Pre-Audit Preparation
- Build or import a custom PSM template covering all 14 elements.
- Schedule audits with automated notifications to relevant personnel.
3.2 On-Site Audit Execution
- Inspectors conduct audits using mobile devices, eliminating paper checklists.
- Collect evidence instantly (photos, video, notes, geo-tagging) for credibility.
- Assign CAPAs in real time with deadlines and responsible persons.
3.3 Corrective and Preventive Actions (CAPA)
- Track open issues until closure with automated follow-ups.
- Provide management with progress dashboards highlighting overdue CAPAs.
3.4 Reporting & Analytics
- Generate instant audit reports with all findings and evidence.
- Use dashboards to analyze trends:
- Most common recurring hazards.
- Areas with weak mechanical integrity.
- Gaps in contractor safety management.
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Benefits of Using eAuditor for PSM Audits
- Efficiency: Replace manual, paper-based audits with automated digital workflows.
- Consistency: Ensure all sites follow the same structured audit process.
- Accountability: Assign responsibilities and track CAPA closures.
- Compliance Readiness: Provide regulators with digital, time-stamped records.
- Risk Reduction: Identify hazards early and prevent catastrophic events.
- Continuous Improvement: Analytics enable proactive risk management strategies.
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Summary
Performing a Process Safety Management Audit using eAuditor allows organizations to digitize OSHA’s 14 PSM elements into actionable checklists, capture real-time evidence, enforce contractor and employee accountability, track CAPAs, and generate compliance reports instantly. By moving beyond paper-based systems, organizations gain visibility, efficiency, and predictive insights that significantly reduce safety risks and strengthen long-term compliance.