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