Location and layout
Site Conditions


Flood control/protection

Prevailing wind

Air or water pollution exposures

Other site conditions requiring attention

Soil protection in storage, materials handling & process areas

Nearby operations

Hazards from

Hazards to



Clearances, hazards

Adequacy of traffic signs


Special requirements imposed by new facility

Storage and handling of chemicals

Buried pipes, tanks or chemical sewer

Leak detection and containment

Above ground storage tanks

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

Bulk dry chemicals

Dust explosion potential addressed

Tanks truck and railcar unloading and loading stations

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


General workplace

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

Human Factors

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


Process Piping

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)

Process Vents

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



Heat Exchangers, Jackets

Vent, drains

Thermal (hydrostatic) pressure relief

Maintenance access (tube bundle)



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

Process Controls/Control Room

Control room inherent safety (vs. process hazards)


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

Utilities Water Supply

No municipal /potable water connections to the process

Steam Boilers and Distribution

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

Compressed Air Systems

Non-lubricated construction or non-flammable synthetic lubricants used for compressor

Discharge pressures above 100 psig


Transformer location

Motor control center(s)

Standby Emergency Utility Systems

Review provisions to satisfy proceeds safety requirements

Waste Handling/Treatment

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

Maintenance Area and Shop


Local exhaust ventilation provided for welding

Locker Room and Lunch Room

Adequate space

Provisions to protect contamination of food by chemicals

Process Safety General

Employee Participation Statement

Process Safety Information

Review of highly hazardous chemicals (HHC) and MSDSs

Block flow diagram

Maximum inventories

Operating limits

Equipment Information


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

Operating instructions clear and easily understood

Instructions adequate (complete)

Material hazards adequately covered for raw materials, catalysts, intermediates,

Products and by-products

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

Process hazards adequately described

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


All pages show revision number and date

Reviewed for correctness

Approved / signed by Department Manager

Responsible Care
Community Awareness and Emergency Response

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

Process Safety

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

Pollution Prevention

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

Industrial Hygiene

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

Local exhaust ventilation systems

Performance of local exhaust ventilation systems

Local exhaust ventilation systems placed on inspection and maintenance program

Control of chemical substances posing a potential occupational mutagenic or carcinogenic risk

Are materials used having control levels A, B, C, or D?

• In the plant

• In the laboratory

Hazard Communication Program

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


Respiratory protection

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


Smoking policy established

Laboratory Control

Process Laboratory Support Plan communicated

Staffing adequate

Laboratory facilities adequate


• 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


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

Operations and Maintenance

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

Commissioning plan and schedule

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

Vessels and piping

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 protection systems

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

Electrical grounding

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

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

Instruments and control systems

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

Water batching

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


Lines and limits of authority clear

Maintenance support

Industrial hygiene monitoring

Equipment monitoring

Performance measurements and tests

Regulatory Compliance

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


• New transport operations adequately reviewed for compliance with all applicable DOT (or equivalent) regulations


• Operating permits obtained as directed by the site or corporate environmental departments


• 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?


• Review equipment for PCB hazardous properties

Supplementary Checklist for New Plant Sites

Plant Security



Visitor controls

Vehicle controls

Restrictions posted



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



Safe and ready for commissioning/startup?