OSHA PSM enforcement is relentless, methodical, and expensive. This site tracks citations, penalties, inspection triggers, and enforcement patterns so covered facilities can see exactly what OSHA is finding — and what it is costing the facilities they find it in.
A National Emphasis Program inspection is not a compliance consultation. Inspectors arrive with a protocol, work through every element of your PSM program, and document every deficiency they find. Each deficiency becomes a citation. Each citation carries a penalty.
These are drawn from OSHA's enforcement database — real facilities, real violations, real amounts. This sample spans common elements and violation types. The full database contains hundreds of records.
| Citation ID | PSM Element | Description of Violation | Type | Penalty |
|---|---|---|---|---|
| PSM-2023-0041 | Process Hazard Analysis §1910.119(e)(1) |
Employer failed to perform a PHA on a covered process. No HAZOP, What-If, FMEA, or equivalent analysis existed for the chlorine process unit exceeding threshold quantity. | Willful | $136,532 |
| PSM-2022-0178 | Mechanical Integrity §1910.119(j)(2) |
Written procedures for maintaining the ongoing integrity of process equipment not developed for pressure vessels and heat exchangers in the covered process. No inspection frequency established. | Repeat | $97,428 |
| PSM-2023-0089 | Operating Procedures §1910.119(f)(1) |
Operating procedures did not include steps for each operating phase — startup, normal operations, temporary operations, emergency shutdown, and emergency operations. Procedures not certified annually. | Serious | $14,502 |
| PSM-2023-0201 | Management of Change §1910.119(l)(1) |
Employer made process changes (equipment substitution, chemical additive introduction) without a documented MOC process. Changes were not reviewed for impact on safety and health. | Willful | $98,114 |
| PSM-2022-0055 | Process Safety Information §1910.119(d)(3)(i)(B) |
P&IDs were not accurate for the covered process. Relief system design basis documentation was incomplete. Material and energy balances were absent for several process units. | Serious | $11,875 |
| PSM-2021-0302 | Pre-Startup Safety Review §1910.119(i)(1) |
No PSSR was conducted prior to startup of a new heat exchanger installed in the covered process. Confirmation that construction was in accordance with design specifications was not documented. | Serious | $13,653 |
Showing 6 of 200+ records — filtered by: All Elements | All Types | All Industries
View Full Database → Filter by Element, Industry, TypeThe penalty isn't random. OSHA applies a structured methodology — violation type determines the ceiling, then gravity, good faith, size, and history adjust the final number. Understanding the structure tells you exactly where your exposure comes from.
Estimate your potential penalty exposure for a single PSM citation. This uses OSHA's published methodology — adjust inputs to model different scenarios.
Inspections are not random. OSHA has a defined priority system. Understanding what moves a facility to the front of the inspection queue is the first step in managing enforcement risk.
These elements generate the most citations across OSHA's PSM enforcement history. Process Hazard Analysis and Mechanical Integrity together account for the majority of all PSM penalty dollars assessed.
The PSM National Emphasis Program directs OSHA area offices to conduct comprehensive, programmed inspections at covered facilities — regardless of complaint history or incident record. If your facility is on the target list, an inspection is a matter of when, not if.
Most facilities that receive willful or repeat citations aren't reckless — they're understaffed, underprepared, or operating with PSM programs that haven't kept pace with facility changes. SafeGuard PSM provides hands-on assessment and gap closure for exactly this situation.