PSSR
Drainage
Flood control/protection
Prevailing wind
Air or water pollution exposures
Other site conditions requiring attention
Soil protection in storage, materials handling & process areas
Hazards from
Hazards to
Vehicular/railroad/pedestrian
Clearances, hazards
Adequacy of traffic signs
Special requirements imposed by new facility
Buried pipes, tanks or chemical sewer
Leak detection and containment
Adequate secondary containment provided
Operating and maintenance access adequate and safe
Adequate and accessible manways
Unobstructed pressure/vacuum relief vents
Manifolding of vents reviewed
Documented vent sizing basis (process safety manuals)
Winterization (including instrument connections)
Adequate lighting
Labeling, placarding of hazards
Other installation details
Flammable and combustible liquids
Tank placement and spacing adequate
Steel supports requiring fireproofing
Flammable liquid breather vents provided with flame arrestors or conservation vents
No flame arrestors on emergency relief vents
Safe vent discharge locations
Vapor-space ignitions hazards
Corporate recommended/approved fire protection systems in place
Flammable gases or liquefied flammable gasses
Corporate recommended/approved fire protection systems in place
Dust explosion potential addressed
Spill containment and safe impounding
Access platform safety
Lighting adequate
Grounding cables
Fixed unloading pump and backflow preventer
Emergency stop button location
Connections lockable and closed
Placarding of hazards
Remotely operated emergency stop valve for vehicles carrying hazardous materials
Fusible-link fire valve on vehicles with bottom unloading of flammable
Portable fire extinguisher at ground level or flammable
Safety shower and eyewash units
Recommended fire protection systems in place
Electrical
Safe operator access
Building exits marked
Lighting adequate
Safety shower and eyewash units
• Accessible
• Located on each deck
• Located in control room
Portable fire extinguishers
• Accessible
• Located on each deck
• Located in control room
Labeling of equipment, piping, critical valves, field instruments, switches
Location of field instruments
Sampling points
Operator task safety
Operator task ergonomics
Opportunities for operator error
Non-routine tasks
Chemical Exposure Hazards
Potential exposures
Engineering controls adequate
Building ventilation/fresh air intakes
Toxic gas monitors, alarms
Protective equipment location
Placarding
Construction appropriate for duty
Materials quality assurance (including flange bolts), if critical, during construction
Workmanship (for example, no short flange bolts)
Routing satisfactory
Adequately supported and guided
Allowance for thermal expansion/no references
No small diameter connections vulnerable to breakage/failure
Expansion bellows properly installed/piping not able to move sideways/bellowed
Undamaged during installation
Flexible piping connectors correctly installed/undamaged (for example, kinked) during installation
Necessary drains provided
Hazardous outlets plugged closed
Thermal (hydrostatic) pressure relief (including heat-traced sections)
Sight glasses and gauge glasses
External corrosion protection
Freeze protection
Insulation adequate for personal protection
Protective flange covers
Approved hoses and hose and connectors (no improvisations)
Flammable liquid breather vents provided with flame arrestors or conservation vents
Telltale pressure gauge or other indicator provided between rupture disc and relief valve where a disc is installed below a relief valve
Discharge piping from emergency pressure relief devices unrestricted by 90 degree ells,
Excessive length or flame arrestors
Provisions such as drain holes to prevent accumulation of rainwater in discharge piping
Discharge piping adequately supported to withstand reactive forces of pressure venting
Safe vent discharge locations
Manifolding of vents reviewed
Vent sizing basis; documentation
Cleanouts
Vent, drains
Thermal (hydrostatic) pressure relief
Maintenance access (tube bundle)
Guarding
Local emergency stop button
Emergency lubrication of critical machinery
Maintenance provisions
Local exhaust ventilation required for shaft seals
Backflow prevention
Connecting piping adequately supported to limit forces on casings
Seal spray protection
Isolation for maintenance
Preparation for maintenance (drain and vent provided)
Spill containment
Fire water runoff
Control room inherent safety (vs. process hazards)
Ventilation
Emergency lighting
Fire protection
Field wiring security
System cable security
Power supply
Operator interface(s)
Alarm systems
Emergency shutdown
Communications - normal and emergency
Software access/security
Software back-up
No municipal /potable water connections to the process
Feedwater treatment chemicals handling
Gas piping routing
Combustion controls
High and low drum water level alarms provided
Bypass around Feedwater regulator accessible from operating level and located where
Drum level gauge glass can be seen
Two independent low water level trips provided for unattended boilers
Dual safety relief valves in service
Relief discharge piping adequately supported and drained
Non-return valve on steam outlet
Distribution piping – see Process piping
Condensate drainage adequate
Non-lubricated construction or non-flammable synthetic lubricants used for compressor
Discharge pressures above 100 psig
Transformer location
Motor control center(s)
Review provisions to satisfy proceeds safety requirements
Inspect new facilities in the same manner as process facilities
Flammable and combustible liquids
Forklifts and Motorized Hand Trucks
Traffic safety
Non combustible fuel
Recommended Fire-Protection Systems in Place
General
Local exhaust ventilation provided for welding
Adequate space
Provisions to protect contamination of food by chemicals
Employee Participation Statement
Process Safety Information
Review of highly hazardous chemicals (HHC) and MSDSs
Block flow diagram
Maximum inventories
Operating limits
Equipment Information
P&IDs
Process Hazard Analysis (PHA) report(s)
All PHA action items completed
Training plan
Contractor work rules
Pre-Startup Safety Review plan
Mechanical Integrity plan
List of critical equipment
Testing program with schedule
Hot Work Permit System
Site Management of Change Procedure
Incident Investigation Plan
Emergency Action Plan (EAP)
Facility EAP written
Are new chemical or process hazards or risks such that changes to existing EAP are required?
Do new facilities create any new transportation emergency response needs and are such needs in place? (Chemtrec update)
Audit Schedule
Operating instructions clear and easily understood
Instructions adequate (complete)
Material hazards adequately covered for raw materials, catalysts, intermediates,
Health hazards and permissible exposure levels (PELs)
Physical hazards
Handling precautions and safe handling procedures including Personal
Protective equipment (PPE) requirements
Corrective respiratory protection specified
Thermal hazards
Any other hazards
Tabulation of process alarms, interlocks (both safety & non-safety) and trips included
Alarm and trip settings given
Specific instruction included, or reference made to separate instructions, for
• Unloading and loading of bulk materials
• Step-by-step process procedures provided for each operating phase including:
• Initial start-up
• Normal start-up
• Normal operation
• Normal shutdown
• Emergency operations including emergency shutdown
• Start-up following emergency shutdown
• Start-up following a turnaround
• Non-routine procedures (for example. equipment clean-out, equipment preparation for maintenance)
• Auxiliary equipment operation
Operating limits clearly defined in step-by-step procedures
Control ranges/limits specified
Consequences of deviations given
Responses to deviations/abnormal conditions specified
Safe hold points specified
PPE caution statements incorporated in step-by step procedures
Use of checklists as appropriate
Up-to-date
All pages show revision number and date
Reviewed for correctness
Approved / signed by Department Manager
Communications training for key employees
Education of employees on EAP, safety, health, and environmental
Education of community on new process or change
Outreach to educate responders, government officials, EAP
Assessment of potential risks to employees from accidents
Communication of emergency planning information to LEPC
Facility tours for emergency responders
Current, complete documentation of process design and operating parameters
Current, complete documentation of hazards of materials and process
Use of site management of change procedure
Use of site incident investigation procedure
Documented sound engineering practices consistent with recognized codes and standards
Mechanical integrity program implemented for new unit or process change
E#mployee Health and Safety
Medical surveillance program tailored to meet needs of new process or change
Personnel change to Central Safety Committee needed
A quantitative inventory of wastes generated and releases to air, water and land
Education of employees and public about the inventory and impact evaluation
Documentation that waste generation is not increased by, or is minimized in, the change or new process
Documentation that waste and release prevention objectives were included the design of the new modified process & products
Review and training of distribution hazards with distributors
Review of transportation routing to minimized potential risks
Review with corporate transportation department
New substances
Health care
Toxicity data available
Accident treatment plan
Need for change in periodic medical exam
Occupational hygiene
Inventory of possible sources of exposure
Inventory means to restrict exposure
Methods available to monitor exposure
Suitable personal protection equipment available
Hearing Conservation
Noise level monitoring needed/arranged for new operations
Engineering and administrative controls adequate
Permissible exposure limits for chemical substances
Appropriate exposure monitoring and evaluation arranged to determine compliance with applicable PELs
PELs for mixtures applied when two or more hazardous substances present
Engineering and administrative controls adequate
Performance of local exhaust ventilation systems
Local exhaust ventilation systems placed on inspection and maintenance program
Are materials used having control levels A, B, C, or D?
• In the plant
• In the laboratory
Location inventory of chemicals updated
Hazardous materials identified in accordance with definitions
MSDSs on file and available to all employees
Chemical containers labeled (or alternate means of label information provided)
Piping labeled
Training
Review/confirm conformance with Corporate Industrial Hygiene Program
Respirator selection in accordance with selection charts and specified in writing
Pressure-demand SCBAs
Emergency “escape only” respirators
User medical clearance
Facial hair policy
Initial issues verified by supervision
Fit testing
Replacement of cartridges and canisters
Inspection and maintenance
Breathing air tested/tagged
Training
Smoking policy established
Process Laboratory Support Plan communicated
Staffing adequate
Laboratory facilities adequate
General
• Emergency exits marked
• Emergency lighting
• Safety shower & eyewash
• Fire protection
Laboratory equipment
• Suitable and adequate
• Maintenance provisions needed
• Storage and handling of chemicals
Reagent storage
• Segregation adequate (oxidizers, acids)
• Flammable liquid storage
• Refrigerator for flammables explosion-proof
Sample storage
• Sample and waste disposal
Compressed gases
• Cylinder location safe (for example, away from heat sources)
• Quantities limited to immediate requirements
• Separation of flammable and oxidizers
• Toxic gas use limited to small cylinders
• Local exhaust ventilation for toxic gases
• SCBAs available for toxic gases
• Personnel trained in SCBA use as needed
Laboratory procedures
• Analytical procedures written and verified
• Sampling procedures included
• PPE requirements specified
• Training completed
• Industrial hygiene
Necessary maintenance information in place
Design drawings: for example as-built P&IDs, electrical schematics, isometric piping drawing
Piping specifications
Equipment purchase orders
Equipment manuals
Vendor prints
Initial inspection and test results
Resources adequate
Needs communicated
Plant personnel
Contract maintenance (arrangements completed)
Shop facilities
Specialized requirements
Requirements defined
Skills available
Equipment available
Procedures developed
Training completed
Certificate obtained and documented
Maintenance management
Service contracts arranged
Maintenance management system in place
Spare parts
Requirements defined by maintenance department
Procurement complete
Start-up needs on hand
Storage security
Quality assurance program in place for critical equipment
Materials of construction/quality of maintenance materials and parts
Workmanship
Preventive maintenance/mechanical integrity program developed
• Machinery
• Boilers and pressure vessels
• Critical equipment, vessels, piping, check valves, expansion bellows, flexible piping connectors, hoses defined
• Critical equipment inspection and test methods and frequencies defined
• Conservation vents, flame arrestors, PSEs, PSVs inspection and test methods and frequencies
• Critical instruments defined
• Proof-testing frequency
• Proof-testing procedures, validity
• Maintenance of combustion safety controls on direct-fired equipment
• Inspection and testing acceptance criteria developed and documented
Initial qualifications of personnel (knowledge and skills)
Training program content vs. needs
Safety orientation for new employees
General safety training
Job-specific training
Basic knowledge and skills
Specialized knowledge and skills
General process knowledge
Material hazards, MSDSs
Process hazards
Process procedures
Operating limits
Consequences of deviations
Responses to deviations/abnormal conditions
Emergency procedures
Field training
Location of:
• Emergency equipment, showers, alarms
• Fire-fighting equipment
• Leak/spill prevention
Reporting, mitigation
Emergency drills
Compliance with OSHA 1910.120 for hazardous waste operations
New emergency response training requirements
Measurement of training
Effectiveness/certification (when applicable)
Formal documentation of training
Team assessment of training effectiveness
Detailed, step-by-step plan written
Plan adequately reviewed
Responsibilities clearly defined and understood
Plant verification of any equipment and systems check-out done by contractor
Construction inspection by plant
Confirm line-by-line conformity to P&IDs verified by plant, including:
Materials of construction
Location of instrument elements/connections
Orifice plate specifications and orientation
Ranges of local PIs and TIs
All local TIs have thermowells
Identifies and relief pressure of PSEs & PSVs
Actuated valve failure modes
Equipment internals
Stress relieving done and documented as required
Field radiography done and documented as required
Pressure/Leak testing done and documented
Cleaned and flushed (instruments, control valves, check valves protected)
Special commissioning requirements (such as chemical cleaning, passivating, or testing)
Vents and pressure relief valves
Shipping supports removed from conservation vents
Relief pressure of PSVs verified by test
Fire water systems inspection and commissioned
Fire water pump acceptance test(s) completed and witnessed
Other non-water fire protection system acceptance test(s) completed and witnessed (for example, CO2 or dry chemical
New fire protection signaling systems and alarms commissioned
Copies of completed test forms forwarded to insurance carrier and Corporate Risk Department
New fire protection equipment, signaling systems and alarms placed on regular inspection and testing programs
Resistance of building and equipment and grounding systems measured <5 ohms
Resistance to ground of all piping sections carrying flammable liquids and combustible powders measured <5 ohms
Ventilation systems balanced
Performance of local exhaust ventilation systems checked for conformance
Alignment checked
Absence of excessive forces on pump casings and other equipment from connected piping
Pre-startup screens installed in pump suctions
Agitator impeller security
Lubrication systems functional
Cooling systems functional
Seal flush systems functional
Rotation checked
Vibration measurements
Performance tests
Other baseline data collection
Program software checked
Instrument loop sheet index available
Pneumatic lines blown clean
Loop checking done and documented
Instrument calibrations done and documented review methods
Alarm and trip points set and documented
Interlocks (both safety & non-safety) tested
Digital control system review and tests
Combustion safety controls on direct-fired equipment
Equipment inspection, adjustment and testing documented
Punch list
Review status
Daily update
Priorities with respect to start-up acceptable
Plan developed
Start-up plan and schedule
Written and reviewed
Procedures for initial start-up specifically covered in the operating
Instruction manual or under separate cover
Reviewed and approved if separate
Raw materials supply
Technical support
Adequate
Lines and limits of authority clear
Maintenance support
Industrial hygiene monitoring
Equipment monitoring
Performance measurements and tests
New Substances
• Review of toxicity to environment
• Persistency in the environment
• Prevention of exposure to environment
• Destruction of substance when necessary
Toxic Substances Control Act (TSCA)
• Project reviewed for any new requirements which might be imposed on the plant location under TSCA
Transportation
• New transport operations adequately reviewed for compliance with all applicable DOT (or equivalent) regulations
Emissions
• Operating permits obtained as directed by the site or corporate environmental departments
Effluents
• New operations covered within the present NPDES permit or a new permit has been obtained
Hazardous wastes
• Determined whether particular wastes qualify as hazardous wastes under federal, state and/or local laws and regulations
• On-site storage, treatment and/or disposal of hazardous wastes
• Reviewed for compliance with applicable laws and regulations, documentation?
• Off-site transportation and disposal of hazardous wastes reviewed with waste coordinator, documentation?
PCBs
• Review equipment for PCB hazardous properties
Plant Security
Access
Fencing
Visitor controls
Vehicle controls
Restrictions posted
Communications
Normal
Emergency back-up
Safety program
• Accountability
• Program conformance with Corporate Safety Standards
• Conformance with group safety standards
• First aid and emergency medical response
• Location procedures written
• Training conducted
• Industrial hygiene program
• Accountability
• Program conformance with Corporate Industrial Hygiene Standards
Fire protection organization
• Location organization
• Level of protection established in accordance with insurance requirement and Corporate Risk Department
• Training conducted in accordance with standard
• Equipment provided in accordance with standard
Municipal fire department (or equivalent)
• Response time and capabilities consistent with location needs and fire protection organization
• Liaison established
• Familiarization
• Drills
Process Safety Management
• Location coordinator appointed
• Program
• Training conducted
Comments/Recommendations
Safe and ready for commissioning/startup?