Pre-Startup Safety Review Checklist

• Facility

• Conducted on

  Date

• Prepared by

• Location
  Address

General Safety

• Have ALL appropriate personnel (Operations, Maintenance, Technical, and Supervision) received adequate and appropriate training on the equipment and operating procedures?

  Yes

  No

  N/A

• Has adequate and appropriate PPE (Personal Protective Equipment) been specified in the Work Procedures and/or Standard Operating Procedures.

  Yes

  No

  N/A

• Has the PPE been provided?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Is the training documented?

  Yes

  No

  N/A

• Have measures been taken to adequately guard all dangerous parts of this equipment?

  Yes

  No

  N/A

• Has sufficient provision been made for the electrical and/or mechanical isolation of the equipment?

  Yes

  No

  N/A

• Are points of isolation clearly marked/labeled and readily accessible?

  Yes

  No

  N/A

• Have bump/trip hazards been properly identified and adequately marked?

  Yes

  No

  N/A

• Have all sharp edges been removed?

  Yes

  No

  N/A

• Has proper guarding, handrails/barriers, been provided to prevent falls?

  Yes

  No

  N/A

• Have all hot/cold surfaces been adequately guarded to prevent burns?

  Yes

  No

  N/A

• Are all cold surfaces adequately insulated to prevent condensation drips (slip hazards)?

  Yes

  No

  N/A

• Are Safety Showers and Eye Wash facilities provided and adequately marked?

  Yes

  No

  N/A

• Are the Safety Showers and Eye Wash facilities routinely inspected?

  Yes

  No

  N/A

• Do the Safety Showers and Eye Wash facilities locations comply with Corporate guidelines?

  Yes

  No

  N/A

• Are the Safety Showers and Eye Wash facilities readily visible and accessible?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Are all of the applicable Work Permit Procedures (Confined Space Entry, Lock Out/Tag Out, Hot Work, High Work, etc.) in place?

  Yes

  No

  N/A

• Have the Operating, Maintenance, and Supervisory personnel been properly trained on the Work Permit Procedures?

  Yes

  No

  N/A

• Has the fire protection systems been inspected by the insurance company?

  Yes

  No

  N/A

• Has acceptance testing been completed and documented?

  Yes

  No

  N/A

• Is there an agreed on test and inspection program for the fire protection systems (including alarm systems)?

  Yes

  No

  N/A

Machinery/Equipment Safety

• Has the machinery/equipment been installed so that it will be stable and secure during operation?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Have slip, trip, trap, crush, entanglement, fall, bump, and cut hazards been minimized?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Is the equipment provided with a clearly identified means to securely isolate it from ALL energy sources?

  Yes

  No

  N/A

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?

  Yes

  No

  N/A

• Has the need to lift, carry, push or pull heavy loads, or parts, been eliminated to the extent possible?

  Yes

  No

  N/A

• Are all display screens, dials and START/STOP/ EMERGENCY buttons positioned so that they are readily visible and accessible by the operating personnel?

  Yes

  No

  N/A

• Have Visual Display Screens been positioned so that interference from glare is reduced to the minimum?

  Yes

  No

  N/A

• 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.)

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

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?

  Yes

  No

  N/A

• Have the health risks been eliminated or are adequate engineering controls utilized to minimize the risks?

  Yes

  No

  N/A

• Has adequate RPE (Respiratory Protective Equipment) been specified in the Operating Procedures?

  Yes

  No

  N/A

• Has the need for an Occupational Health Monitoring Programme been assessed?

  Yes

  No

  N/A

• Has a Monitoring Programme been scheduled?

  Yes

  No

  N/A

• Have the Operating Procedures been reviewed to take into account any additional “health hazards” which may arise from operation or maintenance of this equipment?

  Yes

  No

  N/A

• Has adequate LEV (Local Exhaust Ventilation) been installed, tested, balanced, and entered on an Inspection Schedule?

  Yes

  No

  N/A

• Have adequate inspection/cleaning ports been provided on ductwork?

  Yes

  No

  N/A

• Are relief facilities directed to a safe place away from the workplace?

  Yes

  No

  N/A

• Has a Noise Survey been considered and a Noise Compliance Plan prepared, if required?

  Yes

  No

  N/A

• Has all insulation been identified?

  Yes

  No

  N/A

• Has all pipe work, tanks, and equipment containing hazardous materials been adequately labeled?

  Yes

  No

  N/A

Process Safety

Process Technology

• Are up-to-date Material Safety Data Sheets available?

  Yes

  No

  N/A

• Have the hazardous effects of inadvertent mixing of different materials been considered (that is, has a chemical interaction matrix been prepared/updated)?

  Yes

  No

  N/A

• Has the process design basis been documented or updated?

  Yes

  No

  N/A

• Has the control philosophy and sequence of operations been documented?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Have the recommendations from safety reviews, Process Hazards Analysis (PHA), Hazards and Operability Reviews (HAZOP), CHAZOP, or others, been implemented?

  Yes

  No

  N/A

• Record any incomplete items.

  Yes

  No

  N/A

• Are all relief devices shown on the P&IDs?

  Yes

  No

  N/A

• Are standard markings used on the relief devices?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Have the pressure relief device calculations been provided?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Do the calculations take into the downstream piping?

  Yes

  No

  N/A

• Do the relief devices vent to safe locations?

  Yes

  No

  N/A

• Is containment provided for liquids and solids released from pressure relief devices?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• If yes, Operations must establish control plans to insure that the isolation valves cannot inhibit the operation of the pressure relief devices.

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are the inspection and testing of relief devices in accordance with local regulations?

  Yes

  No

  N/A

Management of Change

• Has a management of change – technology/subtle change document (for example, Change of Design - COD) been approved?

  Yes

  No

  N/A

• Has a test authorization been approved?

  Yes

  No

  N/A

• Are all action items, arising from the COD, that were deemed necessary for start-up, complete?

  Yes

  No

  N/A

• Have all changes made during construction been recorded and authorized?

  Yes

  No

  N/A

• Have hazards evaluations (PHAs, HAZOP, or CHAZOP) been done on all the changes made during construction?

  Yes

  No

  N/A

Process Hazards Analysis

• Have project PHAs been approved and a final project safety report been prepared?

  Yes

  No

  N/A

• Are all action items, deemed necessary by the PHA team for start-up, complete?

  Yes

  No

  N/A

• Has the project been approved as “Safe to proceed with” by the PHA team?

  Yes

  No

  N/A

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)?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• The construction meets the design specifications.

  Yes

  No

  N/A

• The construction matches the drawings.

  Yes

  No

  N/A

• Have the following documented been provided and approved:

  Yes

  No

  N/A

• Instrument indexes and instrument loop diagrams?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• As-built drawings covering P&IDs, electrical, piping, and mechanical?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Welder certification?

  Yes

  No

  N/A

• Non-destructive test (NDT) certifications?

  Yes

  No

  N/A

• Electrical certification for classified areas?

  Yes

  No

  N/A

Mechanical Integrity

• Have maintenance procedures been approved?

  Yes

  No

  N/A

• Have maintenance personnel been trained?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are there adequate inventories of spare parts, operating supplies and maintenance materials?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Have inspections and tests, including regulatory requirements) for the following equipment been included in a maintenance schedule?

  Yes

  No

  N/A

• • Pressure vessels and storage tanks?

  Yes

  No

  N/A

• • Pressure relief systems, vent systems, and devices?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• • Fire protection equipment?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• • Key process-to-service tie-ins?

  Yes

  No

  N/A

• • Electrical earthening, grounding, bonding?

  Yes

  No

  N/A

• • MCC starters?

  Yes

  No

  N/A

• • Emergency alarm and communication system?

  Yes

  No

  N/A

• • Monitoring devices and sensors?

  Yes

  No

  N/A

• • Pumps?

  Yes

  No

  N/A

• • Lifting equipment?

  Yes

  No

  N/A

• Has a reliability engineering analysis been considered/ completed for PSM critical equipment?

  Yes

  No

  N/A

• 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)?

  Yes

  No

  N/A

• Have all commissioning tests or inspections been identified (for example, pressure, or leak tests, passivating procedures)?

  Yes

  No

  N/A

Operating Procedures & Safe Work Practices

• Have standard operating procedures been prepared/updated and approved?

  Yes

  No

  N/A

• Do the operating procedures cover:

• • Initial start-up?

  Yes

  No

  N/A

• • Normal start-up?

  Yes

  No

  N/A

• • Normal operations?

  Yes

  No

  N/A

• • Normal shutdowns?

  Yes

  No

  N/A

• • Emergency operations including emergency shutdowns?

  Yes

  No

  N/A

• • Start-up after emergency shutdowns?

  Yes

  No

  N/A

• • Start-up following turnarounds/prolonged shutdowns?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• • 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?

  Yes

  No

  N/A

• • Safety and operational issues?

  Yes

  No

  N/A

• • Change control procedures?

  Yes

  No

  N/A

Training and Performance

• Has specific process (or job task) training been given to personnel?

  Yes

  No

  N/A

• Have training records been updated?

  Yes

  No

  N/A

Contractor Safety

• Have all contract personnel been adequately trained in appropriate: chemical awareness, maintenance, and operating activities and evacuation procedures?

  Yes

  No

  N/A

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?

  Yes

  No

  N/A

• Did the loop testing confirm that the alarm/interlock (safety & non-safety) action proved, under all conceivable failure conditions, to be fail-safe?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Has all appropriate process technology been updated (for example, interlock lists, P&IDs, logic drawings, etc.)?

  Yes

  No

  N/A

• Does your Control System documentation adequately specify:

  Yes

  No

  N/A

• All major components and their model and serial numbers?

  Yes

  No

  N/A

• All communication cables layout and configuration?

  Yes

  No

  N/A

• Any configurable or custom settings and set-up?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Do you have an appropriate procedure to ensure that your software is protected (for example, routinely archived, key/password protected, etc.)?

  Yes

  No

  N/A

• Has the software been properly documented and filed (for example, logic drawings, schematics, sequence/batch descriptions)?

  Yes

  No

  N/A

• Has all software been properly validated and tested?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

Environmental

• Are all secondary containment/bonding facilities adequate?

  Yes

  No

  N/A

• Are all material storage facilities adequate and appropriately labeled?

  Yes

  No

  N/A

• Have adequate arrangements been made, prior to start-up, for the identification, classification, and safe disposal of all waste materials?

  Yes

  No

  N/A

• Have all materials, used in the system, been entered on the Area Chemicals Inventory List (or equivalent)?

  Yes

  No

  N/A

• Are updated Area Spill Procedures available?

  Yes

  No

  N/A

• Are material Unloading Facilities adequate and constructed in accordance with Corporate Safety, Health, and Environmental Standards?

  Yes

  No

  N/A

• Is there adequate containment (110% of truck volume) in the unloading areas for bulk liquid chemicals?

  Yes

  No

  N/A

• Have the Corporate Environmental Guidelines been followed during the design stage of this project?

  Yes

  No

  N/A

• Have all waste streams been identified, quantified, analyzed and minimized?

  Yes

  No

  N/A

• Are all of the applicable Construction, Environmental and Operating Permits up to-date and approved?

  Yes

  No

  N/A

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?

  Yes

  No

  N/A

• Are fire protection facilities adequate for example, fire extinguishers, fire walls, sprinkler systems, Alarm Boxes, etc.)?

  Yes

  No

  N/A

• Are Emergency Escape Routes, including ladders, adequate and properly signposted?

  Yes

  No

  N/A

• Is emergency lighting adequate?

  Yes

  No

  N/A

• Is sufficient Respiratory Protective Equipment, such as Escape Sets or Self-Contained Breathing Apparatus (SCBA) available?

  Yes

  No

  N/A

• Have Emergency Procedures been prepared and relevant personnel trained?

  Yes

  No

  N/A

• Is the Community Panel advised of proposed new major projects?

  Yes

  No

  N/A

• Has an Electrical Safety Checklist (Acceptance of Electrical Installations) been completed by a competent personnel?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Has equipment been designed and purchased for the conditions under which it will operate (for example, hazardous areas)?

  Yes

  No

  N/A

• Are all live parts adequately enclosed to prevent access?

  Yes

  No

  N/A

• Does grounding and bonding comply with corporate and local standards/legislation?

  Yes

  No

  N/A

• Have fuses or circuit breakers been provided which will automatically disconnect the supply?

  Yes

  No

  N/A

• Are First Aid Stations, single line drawings and PPE requirements available in Motor Control Centers (MCC), Electrical Control Rooms (ECR)/Sub-stations, as appropriate?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Have all new Sub-station Breakers, MCC isolators, starters or other appropriate equipment been registered on to the Site Inspection Schedule?

  Yes

  No

  N/A

• Have any electrical circuits, made redundant by this installation, been properly D&R’d?

  Yes

  No

  N/A

Field verification

• Is the normal lighting adequate for normal and maintenance operations?

  Yes

  No

  N/A

• Is emergency lighting sufficient?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are all instruments, equipment and piping adequately labeled?

  Yes

  No

  N/A

• Is there any rusted and/or damaged equipment?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Is equipment and platform access adequate?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Are safety showers and eye wash stations adequately marked and readily visible?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are all pipelines labeled?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Is all the equipment clearly labeled?

  Yes

  No

  N/A

• Where required are the materials and hazards included on the labeling?

  Yes

  No

  N/A

• Are wall penetrations adequately sealed?

  Yes

  No

  N/A

• Are electrical conduits sealed in accordance with code requirements?

  Yes

  No

  N/A

• Are evacuation routes clearly marked?

  Yes

  No

  N/A

• Are fire extinguishers installed properly?

  Yes

  No

  N/A

• Has the required signage been posted?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Has all scaffolding and construction equipment been removed?

  Yes

  No

  N/A

• Is housekeeping acceptable?

  Yes

  No

  N/A

• Is all required equipment guarding installed

  Yes

  No

  N/A

• Does all the applicable equipment have the required CE marking displayed?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Have noise-monitoring evaluations been completed?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are ear-plugs available near areas exceeding 85 dB?

  Yes

  No

  N/A

Completion

• Comments/Recommendations

• Safe and ready for commissioning/startup?

  Yes

  No

• Engineering

  Sign

• Safety

  Sign

• Quality

  Sign

• Operations

  Sign