Pre-startup safety review checklist
Use this general pssr checklist to determine workplace safety before commissioning a manufacturing facility. this digitized checklist can be edited to fit your pssr needs.
What does this form include?
This form contains 23 sections:
General Safety
- Have ALL appropriate personnel (Operations, Maintenance, Technical, and Supervision) received adequate and appropriate training on the equipment and operating procedures?
- Has adequate and appropriate PPE (Personal Protective Equipment) been specified in the Work Procedures and/or Standard Operating Procedures.
- Has the PPE been provided?
- Have the PPE users been trained in the use of the PPE?
- Is the training documented?
- Have measures been taken to adequately guard all dangerous parts of this equipment?
- Has sufficient provision been made for the electrical and/or mechanical isolation of the equipment?
- Are points of isolation clearly marked/labeled and readily accessible?
- Have bump/trip hazards been properly identified and adequately marked?
- Have all sharp edges been removed?
- Has proper guarding, handrails/barriers, been provided to prevent falls?
- Have all hot/cold surfaces been adequately guarded to prevent burns?
- Are all cold surfaces adequately insulated to prevent condensation drips (slip hazards)?
- Are Safety Showers and Eye Wash facilities provided and adequately marked?
- Are the Safety Showers and Eye Wash facilities routinely inspected?
- Do the Safety Showers and Eye Wash facilities locations comply with Corporate guidelines?
- Are the Safety Showers and Eye Wash facilities readily visible and accessible?
- Has sufficient lighting been provided so that operation, servicing, maintenance, and repair of the facilities can be carried out safely?
- Are notices, dials, screens, etc. for providing operational instructions, safety warnings, and emergency information provided, if required, and positioned so that they are clearly visible and easily read?
- Have all overhead fixtures, for example, pipe-hangers, pipe sleeves, pipe sleeve covers, valve handles, floor opening covers, etc., which could fall or be dislodged, been properly secured?
- Are all of the applicable Work Permit Procedures (Confined Space Entry, Lock Out/Tag Out, Hot Work, High Work, etc.) in place?
- Have the Operating, Maintenance, and Supervisory personnel been properly trained on the Work Permit Procedures?
- Has the fire protection systems been inspected by the insurance company?
- Has acceptance testing been completed and documented?
- Is there an agreed on test and inspection program for the fire protection systems (including alarm systems)?
Machinery/Equipment Safety
- Has the machinery/equipment been installed so that it will be stable and secure during operation?
- Has all access to dangerous moving parts, or danger zones created by the equipment, been prevented by the provision of the correct guards, interlocks (both safety & non-safety) and/or barriers?
- Have the correct safety measures been taken to prevent any risk from hot/cold surfaces, ejection of material, failure of parts and their ejection, overheating/fire?
- Has safe access been provided to the equipment that requires operator and calibration and maintenance personnel access for normal operations, adjustments, service, calibration, maintenance, or repair?
- Have slip, trip, trap, crush, entanglement, fall, bump, and cut hazards been minimized?
- Is the equipment provided with the properly identified START/STOP and EMERGENCY controls that are positioned for safe operation without hesitation, or loss of time, and without ambiguity?
- Is the equipment provided with a clearly identified means to securely isolate it from ALL energy sources?
Ergonomics
- Have the workstations, workplace, or equipment been constructed so that need for stooping, bending stretching, over-reaching and working over-head during operation has been eliminated or minimized?
- Has the need to lift, carry, push or pull heavy loads, or parts, been eliminated to the extent possible?
- Are all display screens, dials and START/STOP/ EMERGENCY buttons positioned so that they are readily visible and accessible by the operating personnel?
- Have Visual Display Screens been positioned so that interference from glare is reduced to the minimum?
- Have workstations been designed and equipped so that the operator can adopt a comfortable position? (That is, able to stand, or change position and sit upright, angle at elbows and knees 90?, feet on floor.)
- Does the operation of this equipment increase the risk of Upper Limb Disorder; for example, repetitive tasks, handling operations, machine paced work and prolonged operation?
Occupational Health
- Have all health risks arising from the gases, liquids, dusts, mists, biological hazards or vapors used by, contained in or emitted by this equipment been assessed?
- Have the health risks been eliminated or are adequate engineering controls utilized to minimize the risks?
- Has adequate RPE (Respiratory Protective Equipment) been specified in the Operating Procedures?
- Has the need for an Occupational Health Monitoring Programme been assessed?
- Has a Monitoring Programme been scheduled?
- Have the Operating Procedures been reviewed to take into account any additional “health hazards” which may arise from operation or maintenance of this equipment?
- Has adequate LEV (Local Exhaust Ventilation) been installed, tested, balanced, and entered on an Inspection Schedule?
- Have adequate inspection/cleaning ports been provided on ductwork?
- Are relief facilities directed to a safe place away from the workplace?
- Has a Noise Survey been considered and a Noise Compliance Plan prepared, if required?
- Has all insulation been identified?
- Has all pipe work, tanks, and equipment containing hazardous materials been adequately labeled?
Process Technology
- Are up-to-date Material Safety Data Sheets available?
- Have the hazardous effects of inadvertent mixing of different materials been considered (that is, has a chemical interaction matrix been prepared/updated)?
- Has the process design basis been documented or updated?
- Has the control philosophy and sequence of operations been documented?
- Has the equipment design basis (for example, BPF’s/P&IDs) been documented/updated?
- Have the recommendations from safety reviews, Process Hazards Analysis (PHA), Hazards and Operability Reviews (HAZOP), CHAZOP, or others, been implemented?
- Record any incomplete items.
- Are all relief devices shown on the P&IDs?
- Are standard markings used on the relief devices?
- Are the relief/rupture pressures included on the P&IDs?
- Have the pressure relief device calculations been provided?
- Was DIERS technology utilized to size the pressure relief devices for all pressure vessels?
- Does the sizing of pressure relief devices agreed with the calculated sizes?
- Do the calculations take into the downstream piping?
- Do the relief devices vent to safe locations?
- Is containment provided for liquids and solids released from pressure relief devices?
- Are there isolation valves that, if closed, will inhibit the operation of pressure relief devices?
- If yes, Operations must establish control plans to insure that the isolation valves cannot inhibit the operation of the pressure relief devices.
- Are all pressure relief devices included in the Preventive Maintenance Program?
- Are the inspection and testing of relief devices in accordance with local regulations?
Management of Change
- Has a management of change – technology/subtle change document (for example, Change of Design - COD) been approved?
- Has a test authorization been approved?
- Are all action items, arising from the COD, that were deemed necessary for start-up, complete?
- Have all changes made during construction been recorded and authorized?
- Have hazards evaluations (PHAs, HAZOP, or CHAZOP) been done on all the changes made during construction?
Process Hazards Analysis
- Have project PHAs been approved and a final project safety report been prepared?
- Are all action items, deemed necessary by the PHA team for start-up, complete?
- Has the project been approved as “Safe to proceed with” by the PHA team?
Quality Assurance
- Have checks and inspections been made to ensure that critical equipment is installed properly and is consistent with design specifications and vendor’s recommendations (for example, alarm and interlock (safety & non-safety) tests; equipment alignment and service to process inter-connections)?
- Have quality assurance inspection reports, covering fabrication, assembly, and installation, been completed in accordance with the project’s quality assurance plan and reports filed with the equipment and design basis documentation?
- List specific items field checked as part of this Pre-Start-up Safety Review to ensure that:
- The construction meets the design specifications.
- The construction matches the drawings.
- Have the following documented been provided and approved:
- Instrument indexes and instrument loop diagrams?
- A tabulation, including settings, of interlocks (both safety & non-safety) and trips (hardwire and software), process alarms and permissive descriptions?
- As-built drawings covering P&IDs, electrical, piping, and mechanical?
- Data sheets for pressure equipment built to ASME or equivalent codes?
- Welder certification?
- Non-destructive test (NDT) certifications?
- Electrical certification for classified areas?
Mechanical Integrity
- Have maintenance procedures been approved?
- Have maintenance personnel been trained?
- Have spare parts listed been developed and entered into the parts ordering software program?
- Are there adequate inventories of spare parts, operating supplies and maintenance materials?
- Have quality control procedures been approved for maintenance materials and spare parts?
- Have inspections and tests, including regulatory requirements) for the following equipment been included in a maintenance schedule?
- • Pressure vessels and storage tanks?
- • Pressure relief systems, vent systems, and devices?
- • Critical controls, interlocks (both safety & non-safety), alarms and instruments?
- • Emergency devices (including shutdown systems and isolation systems)?
- • Fire protection equipment?
- • Piping systems (incl. Components, for example, valves, excess flow valves, expansion bellows) in critical service?
- • Key process-to-service tie-ins?
- • Electrical earthening, grounding, bonding?
- • MCC starters?
- • Emergency alarm and communication system?
- • Monitoring devices and sensors?
- • Pumps?
- • Lifting equipment?
- Has a reliability engineering analysis been considered/ completed for PSM critical equipment?
- Is the equipment inspected by any outside body and certificates on file (for example, CE marking, lifting equipment test certificates, pressure systems regulations, and other items)?
- Have all commissioning tests or inspections been identified (for example, pressure, or leak tests, passivating procedures)?
Operating Procedures & Safe Work Practices
- Have standard operating procedures been prepared/updated and approved?
Do the operating procedures cover:
Training and Performance
- Has specific process (or job task) training been given to personnel?
- Have training records been updated?
Contractor Safety
- Have all contract personnel been adequately trained in appropriate: chemical awareness, maintenance, and operating activities and evacuation procedures?
Interlocks and Alarms
- Has the alarm/interlock (safety & non-safety) been classified and designed by the Project Team? Did the Project Team include members of the PHA team?
- Did the loop testing confirm that the alarm/interlock (safety & non-safety) action proved, under all conceivable failure conditions, to be fail-safe?
- Prior to this PSSR, has an interlock/critical alarm Standard Operating Procedure for testing, through to the final element, been prepared and reviewed/authorized by a competent person for each new or upgraded control system?
- For alarms/interlocks (both safety & non-safety) with more than one software or hardware circuit, have all possible interlock routes been tested?
- Has all appropriate process technology been updated (for example, interlock lists, P&IDs, logic drawings, etc.)?
- Does your Control System documentation adequately specify:
- All major components and their model and serial numbers?
- All communication cables layout and configuration?
- Any configurable or custom settings and set-up?
- Has consideration been given to suitable fire detection and prevention systems for the equipment?
- Do you have an appropriate procedure to ensure that your software is protected (for example, routinely archived, key/password protected, etc.)?
- Has the software been properly documented and filed (for example, logic drawings, schematics, sequence/batch descriptions)?
- Has all software been properly validated and tested?
- Is there verification that the equipment does not re-start, either on the re-setting of a protective device such as an interlock (safety & non-safety), or the re-establishment of power after an outage?
Environmental
- Are all secondary containment/bonding facilities adequate?
- Are all material storage facilities adequate and appropriately labeled?
- Have adequate arrangements been made, prior to start-up, for the identification, classification, and safe disposal of all waste materials?
- Have all materials, used in the system, been entered on the Area Chemicals Inventory List (or equivalent)?
- Are updated Area Spill Procedures available?
- Are material Unloading Facilities adequate and constructed in accordance with Corporate Safety, Health, and Environmental Standards?
- Is there adequate containment (110% of truck volume) in the unloading areas for bulk liquid chemicals?
- Have the Corporate Environmental Guidelines been followed during the design stage of this project?
- Have all waste streams been identified, quantified, analyzed and minimized?
- Are all of the applicable Construction, Environmental and Operating Permits up to-date and approved?
Community Awareness & Emergency Response
- Have all necessary precautions been taken to ensure that the equipment is not a source of ignition to any flammable materials, irrespective of their source?
- Are fire protection facilities adequate for example, fire extinguishers, fire walls, sprinkler systems, Alarm Boxes, etc.)?
- Are Emergency Escape Routes, including ladders, adequate and properly signposted?
- Is emergency lighting adequate?
- Is sufficient Respiratory Protective Equipment, such as Escape Sets or Self-Contained Breathing Apparatus (SCBA) available?
- Have Emergency Procedures been prepared and relevant personnel trained?
- Is the Community Panel advised of proposed new major projects?
- Has an Electrical Safety Checklist (Acceptance of Electrical Installations) been completed by a competent personnel?
- Has the equipment been properly installed and constructed to Corporate guidelines and local legislation, and does it meet any special installation requirements noted on the manufacturer’s certificate?
- Has equipment been designed and purchased for the conditions under which it will operate (for example, hazardous areas)?
- Are all live parts adequately enclosed to prevent access?
- Does grounding and bonding comply with corporate and local standards/legislation?
- Have fuses or circuit breakers been provided which will automatically disconnect the supply?
- Are First Aid Stations, single line drawings and PPE requirements available in Motor Control Centers (MCC), Electrical Control Rooms (ECR)/Sub-stations, as appropriate?
- Have all relevant documentation and drawings (for example, P&IDs, SLDs, Schematics, equipment arrangement, I/O, logic, electrical classification and Panel Schedule drawings) been updated to reflect the current installation?
- Have all new Sub-station Breakers, MCC isolators, starters or other appropriate equipment been registered on to the Site Inspection Schedule?
- Have any electrical circuits, made redundant by this installation, been properly D&R’d?
Field verification
- Is the normal lighting adequate for normal and maintenance operations?
- Is emergency lighting sufficient?
- Are all hot and cold surfaces, which may cause burns, in the proximity of personnel insulated?
- Are all instruments, equipment and piping adequately labeled?
- Is there any rusted and/or damaged equipment?
- Are swing gates or chains installed at the top of ladders and/or on access platforms?
- Are there any gaps between platforms and equipment that could create a foot hazard?
- Is equipment and platform access adequate?
- Do safety showers/eye wash stations create a hazard to personnel (slips), potential for contamination of product (entry to equipment) or ingress to electrical equipment?
- Are safety showers and eye wash stations adequately marked and readily visible?
- Is the access to the safety showers and eye wash stations uninhibited?
- Are all pipelines labeled?
- Are all electrical switches, disconnects, MCCs, control panels, cables, etc labeled?
- Is all the equipment clearly labeled?
- Where required are the materials and hazards included on the labeling?
- Are wall penetrations adequately sealed?
- Are electrical conduits sealed in accordance with code requirements?
- Are evacuation routes clearly marked?
- Are fire extinguishers installed properly?
- Has the required signage been posted?
- Are emergency stops provided where there is a potential for entrapment or exposure?
- Has all scaffolding and construction equipment been removed?
- Is housekeeping acceptable?
- Is all required equipment guarding installed
- Does all the applicable equipment have the required CE marking displayed?
- Does all the applicable equipment have the required UL listing/labeling?
- Have noise-monitoring evaluations been completed?
- Have signs been posted where noise levels excess 85dB?
- Are ear-plugs available near areas exceeding 85 dB?
Comments/Recommendations
Completion
- Safe and ready for commissioning/startup?
Engineering
Safety
Quality
Operations
Use this template