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Pre-Startup Safety Review Checklist

A PSSR checklist is used to determine the safety of a new or modified plant or equipment prior to commissioning. Use this digital PSSR checklist during a Management of Change and tailor the form to your business needs.
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Pre-Startup Safety Review Checklist

PSSR

General Safety

Have all relevant personnel (maintenance, operations, technical and monitoring) received adequate training on equipment and operating procedures?

Has adequate and suitable PPE been specified in the work instructions or standard operating procedures?

Has PPE been provided?

Have the PPE users been trained in the use of it?

Has the training been documented?

Have measures been established to adequately protect all vulnerable parts of this equipment?

Have adequate provisions been made for the electrical or mechanical insulation of the equipment?

Are the insulation points clearly marked or inscribed and easily accessible?

Have any hazards of impact or tripping been properly identified and visibly marked?

Have any sharp edges been removed?

Have protective devices, handrails/barriers, been provided to prevent falls?

Are all hot/cold surfaces well protected to prevent burns?

Are cold surfaces adequately insulated to prevent condensation drops (danger of slipping)?

Are safety showers and eye wash facilities provided and well marked?

Are these safety showers and eyewash units routinely inspected?

Do all locations of safety showers and eyewash facilities comply with company guidelines?

Are the safety showers and eyewash facilities clearly visible and accessible to all employees?

Has adequate lighting been provided so that the operation, maintenance, servicing and repair of the facilities can always be carried out safely?

Are notices, scales, screens, etc., for the provision of operating instructions, safety warnings and emergency information, if required, provided and positioned in such a way that they are accessible and clearly visible to everyone?

Are all devices located on the ceiling, e.g. pipe brackets, pipe sockets, pipe socket covers, valve handles, floor opening covers, etc., which could fall down or come loose, properly secured?

Are any necessary work permit procedures (access to enclosed spaces, lockouts, hot work, high work, etc.) in place?

Have the operating, maintenance and supervisory staff been properly trained in the work permit procedures?

Have the fire protection systems been checked by the responsible insurance company?

Have all acceptance tests been completed and documented?

Is there an agreed test and inspection programme for the fire protection systems (including the alarm system)?

Machinery/Equipment Safety

Have all machines/systems been installed so that they are stable and safe during operation?

Have the correct guards, interlocks (both safety and non-safety) and/or barriers been provided to prevent any access to hazardous moving parts or to danger zones created by the equipment?

Have the necessary safety measures been taken to prevent risks from hot/cold surfaces, material ejection, part failure and ejection, overheating/fire?

Has safe access been provided for operators, calibration and maintenance personnel to carry out normal operation, adjustment, maintenance, calibration, servicing and repair of the equipment?

Have any hazards of slipping, tripping, falling, crushing, entanglement, trapping, bumping or cutting been minimized?

Are all equipment provided with the properly marked START/STOP and EMERGENCY STOP controls necessary for safe, quick and trouble-free operation?

Have all devices been fitted with the necessary controls for safe, quick and trouble-free operation?

Ergonomics

Are the workstations and equipment designed in such a way that the need to bend, bend, stretch, hand over and work overhead during operation is eliminated or minimised?

Has the need to lift, carry, push or pull heavy loads or parts been eliminated as far as 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 the screens been positioned so as to minimize any interference from glare, etc.?

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, 90 degree angle of elbows and knees, feet on floor.)

Does the operation of this equipment increase the risk of upper limb dysfunction, e.g. due to repetitive tasks, handling operations, mechanical work and prolonged operation?

Occupational Health

Have all health risks been assessed which are posed by the gases, liquids, dusts, mists, biological hazards or vapours which are present in, contained in or emitted from equipment?

Have all health hazards been eliminated or are adequate engineering controls in place to minimise the risks?

Has a proper RPE been specified in the operating instructions?

Has the need for an occupational health monitoring programme been assessed?

Is a monitoring program in place?

Have the operating procedures been reviewed to take into account other health risks that may arise from the operation or maintenance of this equipment?

Has an appropriate LEV (Local Exhaust Ventilation) system been installed, tested, balanced and included in an inspection plan?

Have proper inspection/cleaning openings been provided at all ducts?

Are relief facilities directed to a safe place outside the workplace?

Has a noise survey been considered and a plan drawn up to ensure compliance with noise regulations, if necessary?

Has all insulation been identified?

Have all pipes, tanks and equipment containing hazardous materials been properly identified?

Process Safety

Process Technology

Are all current safety data sheets updated?

Have hazardous effects of accidental mixing of different materials been considered (i.e. has a chemical interaction matrix been created or updated)?

Has the process design basis been documented and updated?

Has the equipment design basis (for example, BPF’s/P&IDs) been documented and updated?

Has the control philosophy and sequence of operations been documented?

Have all recommendations from safety reviews, Process Hazards Analysis (PHA), Hazards and Operability Reviews (HAZOP), CHAZOP, etc., been implemented?

Document all incomplete elements:

Are all relief devices shown on the P&IDs?

Are the relief/rupture pressures included on the P&IDs?

Are standard markings used on the relief devices?

Have the pressure relief device calculations been provided?

Does the sizing of pressure relief devices agreed with the calculated sizes?

Was DIERS technology utilized to size the pressure relief devices for all pressure vessels?

Do the relief devices vent to safe locations?

Do the calculations take into the downstream piping?

Are there isolation valves that, if closed, will inhibit the operation of pressure relief devices?

Is containment provided for liquids and solids released from 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 the inspection and testing of relief devices in accordance with local regulations?

Are all pressure relief devices included in the Preventive Maintenance Program?

Management of Change

Has an MOC – technology/subtle change document (such as Change of Design - COD) been approved?

Has the test authorization been approved?

Have all action items resulting from the COD and deemed necessary for commissioning been completed?

Have all changes made during construction been recorded and approved?

Were all modifications made during construction also accompanied by hazard assessments (PHAs, HAZOP or CHAZOP)?

Analysis of Process Hazards

Were the project PHAs approved and a final safety report prepared for the project?

Have all the action items the PHA team deemed necessary to bring the project into operation been completed?

Has the project been approved by the responsible PHA team?

Quality Assurance

Have tests and inspections been carried out to ensure that critical equipment has been installed in accordance with the manufacturer's recommendations (e.g. alarm and interlock tests (safety and non-safety); alignment of equipment and service for processing connections)?

Have the quality assurance inspection reports covering manufacture, assembly and installation been carried out in accordance with the quality assurance plan?

List specific items field checked as part of this Pre-Start-up Safety Review to ensure that:

The design conforms to the relevant design specifications.

The construction matches the drawings.

Have the following documents been submitted and approved:

A tabular listing, including settings, of interlocks (both safety & non-safety) and trips (hardwire and software), process alarms and permissive descriptions?

Instrument indexes and instrument loop diagrams?

As-built drawings that include P&IDs, electrical, piping and mechanical components?

Non-destructive test (NDT) certifications?

Welder certification?

Electrical certification for classified areas?

Data sheets for pressure equipment built to ASME or equivalent codes?

Mechanical Integrity

Have the maintenance procedures been approved?

Have the maintenance personnel been properly trained?

Have all spare parts listed been developed and entered into the parts ordering software program?

Are there sufficient stocks of spare parts, equipment and maintenance materials?

Have quality control procedures been approved for all maintenance materials and spare parts?

Have inspections and tests (including regulatory requirements) been included in a maintenance plan for the following equipment?

• Pressure relief systems, vent systems, and devices?

• Pressure vessels and storage tanks?

• Emergency devices (including shutdown systems and isolation systems)?

• Critical controls, interlocks (both safety & non-safety), alarms and instruments?

• Piping systems (incl. Components, for example, valves, excess flow valves, expansion bellows) in critical service?

• Fire protection equipment?

• Key process-to-service tie-ins?

• MCC starters?

• Electrical earthening, grounding, bonding?

• Monitoring devices and sensors?

• Pumps?

• Emergency alarm and communication system?

• Lifting equipment?

Has a reliability analysis been considered or completed for PSM critical equipment?

Is the equipment tested by an external body and are necessary certificates on file (e.g. CE marking, test certificates for lifting equipment, pressure system regulations etc.)?

Have all commissioning tests or inspections been identified (e.g. pressure or leakage tests, passivation procedures)?

Operating Procedures & Safe Work Practices

Have SOP's been prepared/updated and approved?

Do operating procedures cover:

• The initial start-up?

• The normal start-up?

• Normal operations?

• Normal shutdowns?

• Emergency operations including emergency shutdowns?

• Start-up after emergency shutdowns?

• Start-up following turnarounds/prolonged shutdowns?

• Non-routine procedures such as equipment clean-outs and preparation of equipment for maintenance?

Operation of auxiliary equipment, such as heating/refrigeration systems, LEV and ventilation systems, water systems (soft, RO, WFI, tower systems, etc.), instrument and process air systems, cooling systems (glycol refrigeration systems), waste treatment systems, steam generation and others?

• Change control procedures?

• Safety and operational issues?

Training and Performance

Has personnel been given specific process (or work task) training?

Were the training materials for this also updated?

Contractor Safety

Has all contract staff been adequately trained in chemical awareness, maintenance, operational activities and evacuation procedures?

Interlocks and Alarms

Was the alarm/interlock (both security and non-security) classified and designed by the project team? Did this project team include members of the PHA team?

Did the test loops confirm that the alarm/interlock action (security and non-security) proved fail-safe under all conceivable failure conditions?

Prior to this PSSR, for each new or upgraded control system, has an interlocking/critical alarm operation instruction been prepared for testing down to the last element, and has it been reviewed and authorized by a competent person?

For alarms/interlocks (both safety and non-safety) with more than one software or hardware circuit, have all possible interlock paths been tested?

Have all the necessary procedural techniques been updated (e.g. interlock lists, P&IDs, logic diagrams, etc.)?

Does the Control System documentation adequately specify:

All major components as well as model and serial numbers?

All communication cables layout and configuration?

All configurable or user-defined settings and setups?

Has consideration been given to appropriate fire detection and prevention systems for the equipment?

Do you have a suitable procedure to ensure that the software is protected (e.g. routine archiving, key/password protection, etc.)?

Has the software been properly documented and filed (e.g. circuit diagrams, logic diagrams, sequence/batch descriptions)?

Has all software been properly validated and tested?

Is there a check that the unit will not restart, either when resetting a protection device such as an interlock (safety & non-safety) or when restoring power after a failure?

Environmental

Are the secondary containment/connection devices adequate?

Are the material storage facilities adequate and properly labeled?

Have important precautions been taken to identify, classify and safely dispose of all waste materials prior to commissioning?

Have the materials used in the system been included in the area chemical inventory list (or similar)?

Are updated Area Spill Procedures available?

Are the material unloading facilities properly constructed and in accordance with the company's safety, health and environmental standards?

Is there adequate containment (110% of truck volume) in liquid bulk chemical unloading areas?

Were Corporate environmental guidelines followed at all times during the design phase of this project?"

Have the waste streams been identified, quantified, analyzed and minimized?

Are the applicable construction, environmental and operational permits updated and approved?

Community Awareness & Emergency Response

Have the necessary precautions been taken to ensure that all equipment is not a source of ignition of flammable materials, whatever their source?

Are fire protection devices such as fire extinguishers, fire walls, sprinkler systems, alarm boxes, etc. sufficient?

Are escape routes, including ladders, adequately and properly signposted?

Are the emergency lights adequate?

Is adequate respiratory protective equipment, such as escape sets or self-contained breathing apparatus (SCBA), available?

Have emergency procedures been prepared and the appropriate personnel trained?

Is the Community body kept informed of proposed new major projects?

Has an electrical safety checklist (acceptance of electrical installations) been completed by competent personnel?

Has the equipment been properly installed and built in accordance with company guidelines and local legislation and does it meet the installation requirements stated on the manufacturer's certificate?

Has the equipment been designed and purchased for the conditions under which it will be operated (e.g. in hazardous areas)?

Are all live parts adequately enclosed to prevent access?

Does the grounding and connection comply with company and local standards or laws?

Are fuses or circuit breakers provided to automatically cut off the power supply?

Are first aid stations, paint drawings and PPE requirements available in Motor Control Centers (MCC), Electrical Control Rooms (ECR)/Sub-stations?

Has relevant documentation and drawings (e.g. P&IDs, SLDs, schematics, equipment layout, I/O, logic, electrical classification and panel layout drawings) been updated to reflect the current installation?

Have new switches, MCC isolators, starters or other suitable devices been entered in the inspection plan for the site?

Have electrical circuits that have been rendered superfluous by this installation been correctly suppressed?

Field verification

Is the normal lighting sufficient for work and maintenance?

Is the emergency lighting sufficient?

Are hot and cold surfaces, which may cause burns, in the proximity of personnel insulated?

Are the instruments, equipment and piping adequately labeled?

Is there rusted and/or damaged equipment?

Are the swing gates or chains installed at the top of ladders and/or on access platforms?

Are there gaps between platforms and equipment that could create a foot hazard?

Is the equipment and platform access adequate?

Do safety showers/eye wash stations pose a risk to personnel (slipping), possible product contamination (ingress into equipment) or ingress into electrical equipment?

Are safety showers and eyewash stations adequately marked and clearly visible?

Is access to the safety showers and eye wash stations uninhibited?

Are pipelines labeled?

Are electrical switches, disconnects, MCCs, control panels, cables, etc labeled?

Is the equipment clearly labeled?

Where are the materials and hazards indicated on the label?

Have wall penetrations been adequately sealed?

Are evacuation routes clearly marked?

Are fire extinguishers installed properly?

Are electrical conduits sealed in accordance with code requirements?

Are the emergency stops provided where there is a potential for entrapment or exposure?

Has the required signage been posted?

Is housekeeping acceptable?

Is the required equipment guarding installed

Does the applicable equipment have the required CE marking displayed?

Has the scaffolding and construction equipment been removed?

Does the applicable equipment have the required UL listing/labeling?

Have noise-monitoring evaluations been completed?

Have all signs been posted where noise levels excess 85dB?

Are ear-plugs available near areas exceeding 85 dB?

Completion

Further Recommendations

Safe and ready for commissioning/startup?

Engineering: Name and Signature

Safety: Name and Signature

Quality: Name and Signature

Operations: Name and Signature

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