9 Best Process Safety Management Software for Risk in 2025

Managing high hazard processes means you need software that tracks every change, documents every risk assessment, and proves compliance when regulators show up. You're comparing platforms that promise to streamline OSHA PSM requirements, automate incident reporting, and keep your team aligned on safety protocols. The wrong choice means manual workarounds, missed deadlines, and gaps in your audit trail. The right one becomes the backbone of your process safety program.

We've reviewed nine process safety management platforms that handle everything from hazard analysis and management of change to incident investigation and regulatory reporting. You'll see how each tool approaches PSM compliance, what features matter most for different industries, and where pricing and implementation effort land. We start with 99pt5 BioView, built specifically for BioGas and BioMethane operations, then cover established enterprise solutions and flexible mid market options. By the end, you'll know which platforms deserve a demo and which ones you can skip.

1. 99pt5 BioView

99pt5 BioView targets BioGas and BioMethane plant operators who need real-time monitoring and process safety oversight built specifically for anaerobic digestion systems. The platform connects directly to BioTreater equipment and gives you remote visibility into purification performance, contamination levels, and critical safety parameters. You access everything through a smartphone app, so you can track BioMethane recovery rates, CO2 capture efficiency, and system alarms without being on site.

What 99pt5 BioView does for process safety

BioView monitors desulfurization, oxygen control, and water removal in real time, alerting you when process parameters drift outside safe operating limits. The system tracks catalyst performance in the H2S removal stage and shows you when regeneration or replacement is needed before breakthrough occurs. You get instant notifications for high O2 levels in the BioMethane stream, pressure anomalies, and compressor issues that could trigger safety shutdowns.

Key features for BioGas and BioMethane plants

The platform logs all process data automatically, creating an audit trail that documents safe operation and response to upset conditions. You can view historical trends for flow rates, gas composition, temperature, and pressure across every stage of the BioTreater system. Remote diagnostics let you troubleshoot issues before they escalate, and performance dashboards show you whether your plant is meeting guaranteed 99.5% BioMethane recovery and 99.5% CO2e emission reduction targets.

Compliance and standards support

BioView supports API, ASME, CSA, and EPA compliance by maintaining records that prove your BioGas processing equipment operates within design specifications. The system documents all operational changes and safety events, giving you the evidence base you need for regulatory inspections and permit renewals.

"Built to petroleum industry standards, BioView ensures your process safety documentation meets the same stringent requirements applied to refineries and chemical plants."

Integrations and data flow with existing systems

BioView pulls data directly from sensors and controllers embedded in the BioTreater hardware, so you don't need to integrate with third party SCADA or DCS platforms. The system operates as a standalone monitoring solution that complements your existing farm management or industrial control software without requiring complex API connections.

Who 99pt5 BioView is best for

You should shortlist BioView if you install or operate BioTreater systems and need process safety monitoring that understands the specific hazards of BioGas upgrading. The platform suits system integrators who design complete organics to BioMethane solutions and want guaranteed performance data to share with end clients. Smaller operations benefit from simple deployment and low maintenance, while larger facilities can monitor multiple BioTreater trains from a single interface.

Limitations to consider

BioView works exclusively with 99pt5 BioTreater equipment, so you can't use it to monitor BioGas upgrading systems from other manufacturers. The platform focuses on process monitoring rather than broader PSM requirements like management of change, hazard analysis, or incident investigation. You'll need separate tools or manual processes to handle OSHA PSM documentation, training records, and contractor safety management.

2. SafetyCulture iAuditor

SafetyCulture iAuditor gives you mobile-first inspections and incident reporting built for field teams who need to capture process safety data at the point of work. The platform started as a digital checklist tool and evolved into a broader safety management system that handles audits, observations, and corrective actions across multiple sites. You can deploy it quickly without heavy implementation effort, and your team can start logging safety checks from their phones on day one.

How SafetyCulture supports process safety workflows

The platform lets you convert paper based PSM procedures into digital workflows that guide operators through pre-startup safety reviews, permit to work processes, and equipment inspections. You build checklists that enforce critical safety steps and require photo documentation before tasks proceed. Teams report hazards and near misses in real time, and the system automatically assigns corrective actions to the responsible person with deadline tracking.

Core features for inspections and permits

SafetyCulture provides customizable inspection templates for process equipment, confined space entry, lockout tagout, and other high risk activities. You add conditional logic that triggers follow up questions based on inspection findings, and you require electronic signatures to prove completion. The platform captures photos, timestamps, and GPS coordinates for every inspection, creating an audit trail that documents when and where safety checks occurred.

"Digital checklists ensure consistency and accuracy of pre-startup safety reviews, compliance audits, and risk assessments while maintaining OSHA standards."

Reporting, analytics, and mobile access

You access real time dashboards that show open issues, overdue actions, and inspection completion rates across all locations. The mobile app works offline, so your team can complete inspections in areas without cellular coverage and sync data when connectivity returns. Analytics features help you spot recurring safety gaps and prioritize training or equipment improvements.

Pricing and licensing options

SafetyCulture offers a free tier for teams up to 10 users and a premium plan at $24 per user per month when billed annually. The free version includes basic inspections and reporting, while premium adds advanced analytics, integrations, and priority support. You can trial premium features for 30 days before committing.

When SafetyCulture is and is not a good fit

You should consider SafetyCulture if you need fast deployment of mobile inspection workflows and your PSM requirements focus on routine audits and corrective action tracking. The platform suits operations with distributed teams who need simple, standardized safety checks. Skip it if you require dedicated process hazard analysis tools, management of change workflows, or deep integration with process control systems that demand purpose built process safety management software.

3. Enablon process safety

Enablon by Wolters Kluwer combines process safety management, operational risk, and ESG reporting into a single enterprise platform designed for organizations that manage multiple high hazard facilities. The system treats PSM as part of a broader risk management framework rather than a standalone compliance module, which means you get unified visibility across safety, environmental, and sustainability programs. You can track process hazards alongside environmental incidents, regulatory obligations, and ESG metrics without switching between disconnected tools.

How Enablon approaches integrated risk and PSM

The platform uses a centralized data model that links process safety events to broader operational risks and business objectives. You document process hazards, evaluate their impact on safety and environmental performance, and track mitigation actions within the same workflow that handles other enterprise risks. Enablon builds cross functional accountability by connecting process safety responsibilities to department leaders, contractors, and third party auditors through role based access and automated task assignment.

Hazard analysis, MOC, and audit capabilities

Enablon provides dedicated modules for HAZOP, LOPA, and quantitative risk assessment that guide your team through structured hazard identification and consequence analysis. The management of change system enforces multi stage approval workflows with configurable review gates that require sign off from operations, engineering, and safety before changes proceed. Audit and inspection tools let you schedule recurring process safety audits, capture findings in the field, and escalate non conformances through corrective action workflows.

Strengths for large and complex enterprises

You should consider Enablon if you operate multiple sites with diverse process safety requirements and need a platform that scales across different business units and regulatory jurisdictions. The system handles global deployments with support for multiple languages, regional regulatory frameworks, and site specific risk matrices. Integration capabilities let you connect Enablon to enterprise resource planning, document management, and process control systems to maintain consistent safety data across your organization.

"Enablon's centralized framework supports organization-wide risk management and reporting, ensuring that process safety management software integrates with broader EHS and sustainability initiatives."

Implementation effort and scalability

Enablon requires significant upfront configuration to map your process safety workflows, define risk criteria, and establish approval hierarchies. Expect to spend several months on implementation if you customize the platform to match complex organizational structures or integrate with legacy systems. The platform scales to support thousands of users and hundreds of locations, but this flexibility comes with steeper learning curves for administrators and end users.

Pricing model and typical total cost

Enablon uses enterprise licensing based on the number of users, modules deployed, and sites covered. Pricing is not published, and you need to request quotes directly from Wolters Kluwer. Total cost includes software licenses, implementation services, training, and annual support fees, which can reach six figures for large deployments. Budget for ongoing consultant support if you plan to modify workflows or add new modules after go live.

4. Sphera process safety

Sphera focuses on high hazard process industries where catastrophic incidents create financial, legal, and reputational risks that can shut down operations. The platform builds process safety management software around barrier based risk management, which means you identify what prevents incidents, track barrier health, and respond when barriers degrade. You get tools for process hazard analysis, layers of protection analysis, and bow tie modeling that connect directly to operational data and maintenance records.

How Sphera manages high hazard process risk

The system treats process safety as dynamic risk management rather than static compliance documentation. You map critical equipment, define safety barriers, and link them to real time operational data that shows whether those barriers remain effective. Sphera alerts you when barrier performance degrades based on inspection results, maintenance backlogs, or process deviations that increase likelihood or severity of incidents.

PHA, LOPA, and barrier management features

Sphera provides structured workflows for HAZOP, What If, and FMEA studies that capture hazard scenarios, causes, consequences, and safeguards. The LOPA module calculates independent protection layers and determines whether you meet your risk tolerance criteria for each scenario. Barrier management tracks hardware, procedures, and human factors that prevent or mitigate process safety events, giving you a visual representation of how multiple safeguards work together.

"Barrier based risk management connects process safety documentation to operational performance, ensuring that your safeguards remain effective throughout the asset lifecycle."

Industry focus and deployment options

You should evaluate Sphera if you work in oil and gas, chemicals, mining, or utilities where major accident hazards dominate your risk profile. The platform deploys as cloud or on premise software depending on your data security requirements and integration needs. Sphera supports multi site implementations that standardize risk assessment methods while allowing site specific risk matrices and regulatory requirements.

Data, analytics, and regulatory reporting

The platform aggregates incident data, audit findings, and risk assessments into dashboards that show where your process safety program needs attention. You generate reports formatted for OSHA PSM, EPA RMP, and international standards that compile evidence of compliance from multiple data sources. Analytics features help you benchmark safety performance across sites and identify systemic weaknesses in your process safety management approach.

Pros, cons, and ideal use cases

Sphera excels when you need sophisticated risk modeling and barrier management for complex process facilities. The platform struggles with ease of use and requires trained administrators to configure workflows and maintain data quality. Consider Sphera for large enterprises with dedicated process safety teams and skip it if you need simple, fast deployment or lack internal expertise to support the platform.

5. Honeywell Process Safety Suite

Honeywell Process Safety Suite delivers end-to-end lifecycle management for organizations that operate complex process facilities with integrated control systems. The platform connects PSM documentation directly to operational technology, which means your hazard analyses, safety procedures, and alarm management pull from the same data sources that run your plants. You get unified visibility into process safety risks from design through decommissioning, with tools that support every stage of the safety lifecycle.

How Honeywell covers the safety lifecycle

The suite handles design basis, pre-startup safety reviews, operational readiness, and continuous monitoring within a single system. You document process safety information during engineering, validate that safeguards function correctly before startup, and maintain compliance throughout operations. Lifecycle tracking ensures that safety critical equipment and procedures receive timely reviews, updates, and revalidation as regulations or process conditions change.

Integration with control systems and alarm management

Honeywell connects PSM workflows directly to Experion DCS, Uniformance PHD, and third party control platforms through native interfaces that eliminate manual data entry. The alarm management module analyzes nuisance alarms, operator response times, and alarm floods that degrade process safety performance. You identify which alarms protect against hazards documented in your PHA studies and track whether alarm setpoints match your safety requirements.

"Direct integration with process control systems ensures your process safety management software reflects actual plant conditions rather than outdated documentation."

Features for incident investigation and root cause

The platform provides structured investigation workflows that guide your team through event timelines, causal factor analysis, and corrective action development. You link incidents to specific process hazards and evaluate whether existing safeguards performed as designed. Root cause tools support multiple methodologies including fault tree analysis and barrier failure assessment, helping you prevent recurrence across similar process units.

Cloud, on premise, and hybrid deployment options

Honeywell offers SaaS deployment for cloud native operations and on premise installation for organizations with data residency requirements or legacy system constraints. Hybrid models let you keep sensitive process data on site while using cloud analytics and reporting. Each deployment option supports the same core functionality with differences in infrastructure management and update cadence.

Who should shortlist Honeywell Process Safety Suite

You should evaluate Honeywell if you already use Honeywell control systems and want tight integration between your DCS and PSM programs. The platform suits refineries, chemical plants, and utilities where process control integration reduces data silos and improves alarm rationalization efforts.

6. VelocityEHS process safety

VelocityEHS targets mid market and enterprise organizations that need comprehensive process safety management software without the complexity of platforms built for mega refineries. The system emphasizes management of change and process hazard analysis as the foundation of your PSM program, with modules that handle the 14 elements OSHA requires for compliance. You get a cloud based platform that connects process safety to incident management, training records, and contractor safety through a unified EHS suite.

Focus on MOC, PHA, and operational risk

The management of change module enforces structured approval workflows that require pre change hazard reviews, impact assessments, and post implementation verification. You define multiple change categories with different approval paths, so minor modifications move quickly while major process changes trigger comprehensive safety reviews. Process hazard analysis tools support HAZOP, What If, and Checklist methodologies with templates that guide your team through scenario identification and safeguard evaluation. VelocityEHS tracks action items from PHA studies and sends escalating notifications when deadlines slip.

How VelocityEHS supports OSHA PSM compliance

The platform maintains centralized process safety information including equipment files, operating procedures, and safety data sheets that form the documentary foundation for OSHA compliance. You schedule and track mechanical integrity inspections, pre startup safety reviews, and emergency response drills within the same system that manages your MOC and PHA programs. VelocityEHS generates audit ready reports that compile evidence of compliance across all 14 PSM elements.

"VelocityEHS provides an all-in-one cloud software system for planning, coordinating, executing and tracking changes to covered processes to ensure comprehensive assessment and communication of risks from start to completion."

Usability, workflows, and mobile tools

The interface uses intuitive dashboards that show open action items, upcoming compliance deadlines, and process safety metrics without requiring extensive training. Mobile apps let your team log observations, submit change requests, and complete inspections from the field with offline capability. Workflow automation routes tasks to the right approvers and sends reminders when reviews are overdue.

Integration with broader EHS management

VelocityEHS connects process safety directly to incident management, training, and audit modules that share common user profiles and organizational structures. You link process hazards identified in PHA studies to incident investigations and training requirements, creating visibility into how different EHS programs support your safety goals. The platform integrates with document management systems and HRIS platforms to maintain current employee certifications.

Pricing tiers and best fit organizations

VelocityEHS uses per user per month pricing that varies based on which modules you license and how many users need access. You should request quotes directly since published pricing is not available. Consider VelocityEHS if you need comprehensive PSM coverage with strong MOC and PHA tools integrated into a broader EHS platform, and skip it if you require specialized barrier management or deep process control integration.

7. Quentic process safety

Quentic delivers modular process safety management software that lets you build your PSM program incrementally rather than deploying a massive platform all at once. The system separates risk assessment, incident management, audit, and compliance modules so you license only the functionality you need today and add capabilities as your program matures. You connect Quentic modules through a shared database that eliminates duplicate data entry and maintains consistency across different safety processes.

Modular approach to EHS and PSM

The platform treats process safety as part of your broader EHS strategy rather than an isolated compliance program. You start with core PSM modules for hazard analysis and management of change, then expand to include environmental compliance, occupational health, and sustainability reporting using the same interface and user permissions. Each module shares common workflows for task assignment, approvals, and escalations that reduce training time when you add new capabilities.

Risk assessment, incident, and action tracking

Quentic provides structured templates for process hazard analysis that walk your team through hazard identification, consequence evaluation, and safeguard documentation. The incident module lets you link events directly to process hazards identified in your risk assessments and track whether existing safeguards performed as designed. Action tracking ensures that corrective measures from incidents and audits move to completion with automated reminders and status reporting.

"Data and trend analysis track performance and drive improvements, helping you identify systemic weaknesses in your process safety management approach."

Collaboration and document management strengths

The platform supports multi user collaboration on risk assessments and investigations with real time updates that prevent version control issues. Document management features maintain controlled access to process safety information including operating procedures, equipment specifications, and safety data sheets that form your PSM foundation.

Deployment models and implementation timelines

Quentic deploys as cloud based software that eliminates on premise infrastructure requirements and accelerates go live timelines. You can configure basic PSM workflows within weeks rather than months if you use standard templates and minimize customization.

When Quentic makes the most sense

You should evaluate Quentic if you want flexibility to scale your PSM program gradually and need integrated EHS management rather than point solutions. The modular pricing lets you control costs while building comprehensive safety coverage across your organization.

8. TenForce and SAI360

TenForce and SAI360 both offer integrated EHS platforms that extend beyond process safety into broader risk and compliance management. You get PSM capabilities packaged with environmental compliance, sustainability reporting, and operational risk tools that share common data models and workflows. Both platforms target mid market to enterprise organizations that need scalable solutions without the complexity of specialized process safety systems.

TenForce overview and key capabilities

TenForce provides workflow automation for compliance tasks including management of change, risk assessments, and training management. The platform emphasizes contractor management and permit to work processes that control third party access to your facilities. You configure safety workflows using visual designers that let non technical users modify approval paths and notification triggers.

SAI360 overview and key capabilities

SAI360 combines incident reporting, investigation workflows, and action tracking within a governance, risk, and compliance framework. The platform supports process hazard analysis and audit management while maintaining broader enterprise risk registers. You access performance analytics through customizable dashboards that show safety metrics alongside other operational risks.

Risk and compliance features compared

Both platforms handle basic PSM elements including hazard identification, MOC, and incident management. TenForce focuses on operational workflows and contractor safety, while SAI360 emphasizes enterprise risk integration and audit capabilities. Neither platform provides specialized tools for LOPA, bow tie modeling, or deep process control integration found in dedicated process safety management software.

Industries and use cases each suits best

TenForce suits construction, manufacturing, and facilities management where contractor safety and permit to work processes drive compliance. SAI360 fits organizations with mature GRC programs that need PSM alongside financial, cybersecurity, and strategic risks.

"Both platforms work best when you need integrated EHS management rather than specialized process safety capabilities for high hazard facilities."

Pricing, deployment, and scalability

Both vendors use per user pricing models that vary based on modules licensed and deployment size. You need to request quotes directly since published pricing is not available. Cloud deployment is standard for both platforms with implementation timelines ranging from weeks to months depending on customization requirements.

How to choose between TenForce and SAI360

Choose TenForce if you prioritize contractor management and operational workflows with strong mobile access. Select SAI360 when you need enterprise risk integration and deeper audit capabilities that connect process safety to broader compliance programs.

Final thoughts

You've reviewed nine process safety management software platforms that span simple mobile inspection tools to enterprise risk management suites. Each platform handles different aspects of PSM compliance, from hazard analysis and management of change to incident investigation and regulatory reporting. Your choice depends on your industry, facility complexity, and integration requirements rather than feature counts or vendor marketing claims.

BioGas and BioMethane operators face unique process safety challenges that generic EHS platforms don't address directly. You need monitoring tools that understand desulfurization, oxygen control, and the specific hazards of biogas upgrading. Standard process safety management software wasn't built with anaerobic digestion in mind. If you design or operate biogas-to-biomethane systems and need guaranteed performance data alongside safety monitoring, explore how 99pt5 BioView delivers real-time oversight built specifically for your operations. The platform tracks safety parameters that matter for your process while documenting the compliance evidence regulators expect during inspections and permit renewals.