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)?
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?
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?
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?
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?
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?
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?
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?
Non-destructive test (NDT) certifications?
Electrical certification for classified areas?
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?
• 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)?
Have standard operating procedures been prepared/updated and approved?
Do the operating procedures cover:
• Initial start-up?
• 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 procedure such as equipment clean-outs and preparation of equipment for maintenance?
• Auxiliary equipment operations including as examples; LEV and Ventilation Systems, Heat/Cool Skids, Water (Soft, RO, WFI, Tower, etc.) Systems, Instrument and Process Air Systems, Waste Treatment Systems, Cooling (Glycol Refrigeration) Systems, Steam Generation, and others?
• Safety and operational issues?
• Change control procedures?
Has specific process (or job task) training been given to personnel?
Have training records been updated?
Have all contract personnel been adequately trained in appropriate: chemical awareness, maintenance, and operating activities and evacuation procedures?
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?
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?
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?
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?
Safe and ready for commissioning/startup?