PSSR Checklist | Lumiform

PSSR checklist

About the PSSR checklist

Using a PSSR (Pre-Startup Safety Review) checklist template is crucial for ensuring comprehensive safety checks before starting any new process or equipment. This template helps you systematically cover all critical safety aspects, reducing the risk of accidents and non-compliance. By using a template, you can optimize your safety review process and enhance workplace safety. A PSSR checklist template serves you by providing a clear, repeatable process. You can use this template to ensure every safety check is documented, from equipment inspections to safety system verifications. This consistency helps maintain high safety standards and improves regulatory compliance. Make the most of our template by customizing it to fit your specific needs. Whether you manage a small facility or a large industrial site, a well-organized checklist ensures all team members follow the same procedures, reducing errors and increasing efficiency.

Key elements of a PSSR checklist template

Understanding the key elements of a PSSR (Pre-Startup Safety Review) checklist template helps you create a thorough and effective safety review process. Here are four essential components to include:

Equipment and system inspections: This section ensures that all equipment and systems are inspected for functionality and safety. By documenting these checks, you can identify and address potential issues before they become hazards, enhancing operational safety.
Safety system verifications: Include checks for safety systems such as alarms, emergency shut-offs, and fire suppression systems. Verifying these systems ensures they are operational and ready to protect personnel and equipment in case of an emergency.
Compliance checks: Ensure that all processes and equipment comply with relevant safety regulations and standards. This component helps you maintain regulatory compliance and avoid potential fines or shutdowns due to non-compliance.
Documentation and training: Provide space for documenting training sessions and safety briefings conducted with personnel. Ensuring that all team members are trained and aware of safety protocols is crucial for maintaining a safe working environment.

Best practices for using a PSSR checklist template

To get the most out of your PSSR (Pre-Startup Safety Review) checklist template, follow these best practices. First, ensure accurate documentation. Record all safety checks and findings meticulously. This helps maintain comprehensive records and provides a clear audit trail for future reference. Second, prioritize critical checks. Focus on essential safety systems and equipment that have the highest impact on operational safety. This ensures that major risks are identified and mitigated early. Third, use clear and concise language in the checklist. This makes it easier for team members to understand and follow, reducing the chance of errors and ensuring that all tasks are completed correctly. Fourth, regularly update the checklist. Incorporate new safety procedures and industry best practices to keep your checklist relevant and effective. This ensures that your team is always following the latest guidelines and providing top-notch safety reviews. By following these tips, you can optimize your PSSR process and ensure high safety standards. A well-organized checklist helps streamline tasks, improve efficiency, and enhance overall workplace safety.

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Preview of the template

PSSR

Information

Equipment/Facility

Equipment name

Location of Equipment

Facility name

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 they been ordered and distributed to the appropriate personnel?

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?

Are maintenance personnel trained to perform the plant maintenance?

Can the machine be oiled without removing the safeguards?

Is there more than one operator?

Are separate controls provided?

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?

Has ventilation been installed?

If ventilation has not been installed, have employees been instructed in temporary hazard abatement procedures?

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?

What is the nature of the hazard?

Identify hazard

Permit required for confined spaces?

Are all hatches and other means of entry labeled as confined spaces?

Have space specific entry procedures been developed?

Have employees been trained on entry procedures?

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?

Has the training been conducted?

Have new training requirements forwarded to the Training Department?

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?

Completion

Comments/Recommendations

Safe and ready for commissioning/startup?

Engineering

Safety

Quality

Operations

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This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.