Pssr checklist
A pre-startup safety review (pssr) checklist is a tool used by a pssr team during a safety review of a new or modified manufacturing facility before commissioning. this checklist helps ensure that a facility will be safe for employees and that equipment will operate according to design specifications.
What does this form include?
This form contains 27 sections:
Equipment/Facility
PSSR Team Members
Lockout/Tagout
- Is the machine capable of being locked out?
- Has the equipment specific lockout/tag out procedure been developed?
- Are there any special lockout devices needed?
- Have sanitation, production, and maintenance employees been properly trained on the lockout procedures?
Mechanical Hazards
- Are equipment disconnects and operating controls labeled?
- Are the start and stop controls within easy reach of the operator?
- Is there plant maintenance for the equipment?
- Can the machine be oiled without removing the safeguards?
- Is there more than one operator?
- Are Emergency Stops working and accessible to the operator?
Machine Guarding
- Have all pinch points and points of operation been properly guarded?
- Have all chains and sprockets been properly guarded?
- Are there any exposed set screws, key ways, collars, etc?
- Have all pulleys and belts been properly guarded?
- Have augers (if present) been properly guarded?
- Are all machine guards securely attached?
- Are interlocks prohibited from being bypassed if applicable?
- Test all interlocks to ensure functioning properly if applicable?
- For saw blades, is only the length necessary to cut product exposed?
- Are all shafts ends covered with a non-rotating cap or cut down to a length of less than 1/2 the diameter of the shaft?
Electrical
- Is the machine wired according to code? (National Electric Code, National Fire Protection Association)
- Is the machine grounded?
- Is the power supply correctly fused and protected?
- Will additions or modifications require an Arc Flash analysis?
- Are all electrical connections secured, cords only the length necessary, conduit only used where required (no cords running through walls, under doors, etc)?
- Is there any temporary equipment S/O cord (allowed for only 90 days) if any follow up required?
Personal Protective Equipment (PPE)
- Has PPE Hazard Analysis been conducted for new jobs?
- Is required PPE available and issued to operators?
- Have operators been properly trained in the use and care of required PPE?
Noise
- Have appropriate measures been taken to safeguard workers against noise hazards?
- Has an area survey been conducted?
- If noise is above 85 dB, has noise reduction measures been considered?
Evacuation/Egress
- Have existing means of egress been obstructed or changed (at least 28")?
- Have exit routes been rerouted if necessary?
- Have employees been trained in new exit routes?
- Has the emergency evacuation drawing been updated?
- Is head room at least 7 feet high with no overhead obstructions below 6'8"?
- Have all emergency exits been designated by appropriate signage/lighting?
- Are new sprinkler systems operational and tested?
- Fire Extinguisher accessible and adequately marked?
Ventilation
- Does the new equipment generate hazardous vapors/gasses/fumes which will require additional ventilation?
Ergonomics
- Has an ergonomic audit (ergonomic job measurement system, ergonomic assessment) been conducted of the new/modified equipment?
- Have identified ergonomic hazards been corrected?
Confined Spaces & Hazardous Locations
- Has the new equipment created a hazardous location?
- Permit required for confined spaces?
- Are all hatches and other means of entry labeled as confined spaces?
Fall Protection
- The new equipment will not create a situation in which employees must work more than 4' above the floor and outside of a standard guard rail?
- Has appropriate fall protection equipment been provided to employees?
- Have employees been trained in the use of required fall protection equipment?
- No slip/trip/fall hazards created?
Hazard Communication
- The new equipment has not introduced any new hazardous chemicals into the facility?
- Have employees been trained in the hazards and protective measures for the new chemical?
Training
- Does the new/modified equipment require additional process training?
Food Safety
- Is the new equipment designed and manufactured to be easily cleaned?
- Is there a standard operating procedure in place to break down the equipment for cleaning?
- Has USDA been notified of the addition and the start up of the equipment?
- Has the cleaning contractor been notified of the addition and the startup date of the equipment?
Air Permits
- Has equipment received the necessary air permits?
- Has the regulatory agency been notified of start up?
- Has a standard operating procedure been modified or created to control the equipment per regulations?
- Has an updated standard operating procedure been submitted to regulators for approval?
- Does the facility have spare/redundant critical equipment to keep equipment running within compliance standards?
Wastewater Compliance
- Has the equipment received the necessary wastewater permits and/or notifications?
- Has a standard operating procedure been modified/created to control the equipment to not impact wastewater?
- Is wastewater treatment operations prepared to handle the impact of this process change?
SPCC/Storm water
- Are secondary containment and/or storm water controls in place?
- Has the SPCC plan been updated, including site maps?
- Has a "best management practice" been created for this potential pollution source?
ISO 14001
- Are the necessary "Operational Controls" established and documented in the environmental management system?
- Have any new reporting requirements been added to the environmental calendar?
- Is the process change an Aspect or Significant Aspect?
- Has the training schedule been updated to include the process change?
Waste/Chemical Notification /Utilities
- Are the procedures in place to handle the waste (hazardous or non-hazardous) from the process change?
- Has notification to regulators occurred to address legal requirements?
- Are appropriate back flow connections installed to prevent contamination of potable water?
- Are the appropriate mechanical and procedural systems installed to minimize energy/water usage?
Comments/Recommendations
Completion
- Safe and ready for commissioning/startup?
Engineering
Safety
Quality
Operations
Use this template