化工廠常用PSSR檢查表

1、化工廠常用PSSR檢查表PSSR清單例如A-1Description of System/Area Under Review所審查系統(tǒng)/區(qū)域的描述Date日期Time時(shí)刻List of Participants參與者名單Circulation: those present plus傳閱：加入人員加上Comments探討ItemNo.序號(hào)Recommendation(Type Action Below or not applicable)建議（請(qǐng)?zhí)顚懸韵滦袆?dòng)項(xiàng)或注明“不適用）Department / ResponsiblePerson部門/責(zé)任人CompletedDate完成日期Review H

2、AZOP list for applicable actions查看HAZOP列表看相關(guān)行動(dòng)項(xiàng)是否解決Review CHAZOP list for applicable actions查看CHAZOP列表看相關(guān)行動(dòng)項(xiàng)是否解決Review punch list for applicable actions.查看剩余工作清單看相關(guān)行動(dòng)項(xiàng)是否解決Noise level monitoring (document)噪音等級(jí)監(jiān)測(cè)（文件）Exposure monitoring (document)操作人員暴露風(fēng)險(xiǎn)監(jiān)測(cè)（文件）Emissions permits排放許可Other operating permi

3、ts其他承諾的行動(dòng)System Checkout Items系統(tǒng)檢查工程系統(tǒng)檢查條目Complete/document quality assurance program:完成質(zhì)量保證體系并建立了文檔Received equipment=purchased收到的設(shè)備=購(gòu)買的設(shè)備Adherence to design drawings/specifications采用的設(shè)計(jì)規(guī)范Materials of construction施工材料Workmanship工藝技術(shù).Equipment components checkout/commissioning (document)設(shè)備部件檢查/調(diào)試（文件

4、）Loop and interlock/permissive/alarm: set point adjustment and testing (document results)回路和聯(lián)鎖/許可/報(bào)警：設(shè)置點(diǎn)調(diào)整和測(cè)試（文檔記錄）Instrument calibrations done and documented外表校訂完成并記錄Validation protocol developed, approved and executed制定、批準(zhǔn)和執(zhí)行的驗(yàn)證協(xié)議Pressure testing done and documented壓力測(cè)試完成并記錄System cleaned and flus

5、hed系統(tǒng)已完成清掃、沖洗Fire protections systems inspected, acceptance-tested documentation provided消防系統(tǒng)已檢查，并有測(cè)試、驗(yàn)收記錄Ventilation systems balanced通風(fēng)系統(tǒng)已平穩(wěn)Performance checkout of local exhaust systems局部排氣系統(tǒng)的性能檢測(cè)Vibration measurements/documentation振動(dòng)測(cè)量記錄Field radiography done and documented as required現(xiàn)場(chǎng)放射性物質(zhì)檢測(cè)已完成

6、并記錄Baseline data, such as thickness readings for pressure vessels/piping基礎(chǔ)數(shù)據(jù)，如壓力容器/管線的壁厚Other baseline data其他基礎(chǔ)數(shù)據(jù)NDT reports無損檢測(cè)報(bào)告Water batching (document)配水（記錄）Engineering Design Documentation工程設(shè)計(jì)資料Narrative of control philosophy/Sequence of operations documentation操作操縱原理/操作順序的說明資料Instrument index外

7、表索引Instrument loop diagrams外表回路圖Interlock (safety & non-safety) descriptions聯(lián)鎖（安全和非安全）描述As-built drawings: P&IDs, electrical, piping, mechanical竣工圖：PID圖，電氣圖，配管圖，機(jī)械圖Tabulation of process alarms, interlocks/permissive descriptions and trips with settings (P&ID)工藝報(bào)警表、聯(lián)鎖/許可說明表和帶設(shè)定值(P&ID)的跳轉(zhuǎn)表Review and a

8、pproval of fire protections systems design消防系統(tǒng)設(shè)計(jì)的審查和許可Piping specifications (P&I/mechanical drawings)配管圖（PI圖 /機(jī)械圖）Pressure relief device sizing calculations安全閥規(guī)格的選定運(yùn)算ASME code pressure vessels U-1 data sheets (to Maintenance) 壓力容器ASME代碼U-1數(shù)據(jù)表（用于修理）Reference codes/standards for facility design裝置設(shè)計(jì)的參考

9、規(guī)范/標(biāo)準(zhǔn)Reference codes/standards for facility installation設(shè)備安裝的參考規(guī)范/標(biāo)準(zhǔn)Design codes for specific equipment特意設(shè)備的設(shè)計(jì)規(guī)范Welder certification焊工資格證書NDT certification無損檢測(cè)證書Electrical classification drawings電器分類圖Electrician certification for classified areas特定施工區(qū)域的電工資格證書Maintenance Items修理工程Spare parts lists de

10、velopedList equipment:備品備件清單并附設(shè)備清單Stock required spare parts備品備件所需儲(chǔ)存設(shè)施Equipment manuals/specifications to Maintenance and Operating Department修理和操作部門的設(shè)備手冊(cè)/說明Vendor prints供給商提供的印刷資料Submit preventive maintenance requests (PMs)提交的預(yù)防性修理要求Service contracts in place服務(wù)合同已簽訂Train maintenance personnel and d

11、ocument培訓(xùn)修理人員和相關(guān)培訓(xùn)資料Operational Items生產(chǎn)工程Develop SOP and special procedures incorporate safety and operational issues:編寫標(biāo)準(zhǔn)操作規(guī)程（SOP）及特意操作規(guī)程考慮了操作風(fēng)險(xiǎn)和可操作性問題Complete change control authorizations完成變更操縱授權(quán)Develop/issue operating procedures:制定/公布以下操作規(guī)程Initial start-up初次開車Normal start-up正常開車Normal operation正

12、常操作Normal shutdown正常停車Emergency operations including emergency shutdown包括緊急停車的應(yīng)急操作Start-up following emergency shutdown緊急停車后開車Start-up following turnaround大修后開車Non-routine procedures (equipment clean-out, equipment preparation for maintenance)特意規(guī)程序（設(shè)備清理、設(shè)備修理預(yù)備）Auxiliary equipment operation輔助設(shè)備的操作Tra

13、in operating personnel and document培訓(xùn)操作人員和相關(guān)培訓(xùn)資料Provide technical coverage技術(shù)服務(wù)范疇What is the probability of containment failure? What are thesubsequent consequences? Review spill containment, rainwater runoff, and fire water containment.防泄漏設(shè)施的失效概率是多少？失效的后果是什么？審查防泄漏設(shè)施、雨水流量和消防水容量Electrical Issues電氣問題Pa

14、nel access, clearance around panel, keys, etc.配電盤的通道、配電盤周邊的間隙、鑰匙等Cable entry section glanding, housekeeping and other issues電纜接入部分密封、保潔及其他問題Panel power source identified? Multiple feeds? 配電盤電源的標(biāo)識(shí)？多源供電？Space heaters required?需要空間加熱器嗎？Lighting in panels配電盤里的照明Canopies etc. for outdoor panels用于室外配電盤的雨棚

15、等Protection settings available?有愛惜設(shè)置嗎？Panel board schedules配電盤面板清單Spare capacity available?有備用容量嗎？PPE available? HV mats, gloves有個(gè)人防護(hù)用品嗎？有高壓絕緣墊嗎? 有高壓絕緣手套嗎?Emergency/Standby power required?有應(yīng)急/備用電源嗎？VSD settings available factory/commissioning變頻器設(shè)置工廠/調(diào)試Room access, permitting, maintainability, ingres

16、s/egress of equipment房間通道、許可證、可修理性、設(shè)備的進(jìn)出通道Pockets for drawings in panels?配電盤的圖紙集Voltage warning labels?電壓警告標(biāo)簽Ventilation sufficient?通風(fēng)充實(shí)嗎？Suitability for area - IP rating, GMP suitability, hazardous area classification.區(qū)域適合性國(guó)際防護(hù)等級(jí)、GMP適合性、危險(xiǎn)區(qū)域分類Relief Devices泄放設(shè)備Are there standard markings on the P&I

17、D?在P&ID圖上有標(biāo)準(zhǔn)代號(hào)嗎？Do relief lines vent to a safe location?放空線排放到一個(gè)安全地點(diǎn)嗎？Are relief lines and relief devices secured and adequately sized?放空線和泄放設(shè)備安全嗎?尺寸足夠大嗎？Are there any isolation valves which will inhibit operation of relief valves if closed? If YES, nominate Operations to monitor. If NO, record no.有

18、處于關(guān)閉狀態(tài)會(huì)抑制放空閥操作的隔離閥嗎？假使有，請(qǐng)指定操作人員對(duì)其進(jìn)行監(jiān)視。假使沒有，記錄無Is there a standard operating procedure for relief devices in place?現(xiàn)場(chǎng)有泄放設(shè)備的標(biāo)準(zhǔn)操作規(guī)程嗎？For Field Verification現(xiàn)場(chǎng)確認(rèn)Is lighting sufficient?照明充實(shí)嗎？Is emergency lighting sufficient?應(yīng)急照明充實(shí)嗎？Are steam pipes, valves, or traps situated within proximity of people insu

19、lated?位于人接近范疇內(nèi)的蒸汽管線、閥門或疏水器被隔離了嗎？Is all instrumentation identified and tagged?所有的外表都有標(biāo)識(shí)和掛牌了嗎？Is there any rusted or damaged equipment?有任何生銹或損壞的設(shè)備嗎？Are swing gates installed on top of ladders or on access platforms?在梯子頂部或平臺(tái)通道上安裝了止回門嗎？Review edge protection on platforms and heights. Will it protect per

20、sonnel and equipment? Is access adequate? 檢查平臺(tái)和高處的邊緣愛惜。它能愛惜人員和設(shè)備嗎？通道足夠嗎？Do safety showers provide a hazard to people (slips), product (contamination of systems), or ingress to electrical switchgear or equipment?安全噴淋對(duì)人(滑跤的危險(xiǎn))、產(chǎn)品（系統(tǒng)的污染）或內(nèi)部的電氣開關(guān)柜或設(shè)備產(chǎn)生危險(xiǎn)了嗎？Are safety showers supplied from tempered water

21、?安全淋浴供給熱水嗎？Is chemical dosing within a safe proximity of people and product?化學(xué)品操作是在人和產(chǎn)品安全接近范疇內(nèi)嗎？Label all pipe lines標(biāo)識(shí)所有的管線Label all electric switches, disconnects, MCCs, control panels, cables, etc.標(biāo)記所有的電氣開關(guān)、中斷器、電動(dòng)機(jī)操縱器、操縱盤和電纜Label vessels (material, hazard warnings)List:標(biāo)記容器（材料、危險(xiǎn)警告）的清單Seal wall pe

22、netrations密封墻壁的滲透Pour conduit seals灌注導(dǎo)管的密封Install fire extinguishersEvacuation routes postedInstall appropriate area signsIs all scaffolding and equipment removed; is general housekeeping acceptable?If there is potential for entrapment or exposure, has an E-Stop been provided?If full guarding is in

23、place, has a lockable isolation device been provided?Pest control required in room/building?MSDS sheets required?Sprinklers in rooms?Single point of failure condition? Has it been identified? Record.PSSR Checklist Example A-2Pre-startup Safety Review ChecklistInspection Date:Department/Area:Project

24、Number:Title/Equipment:Signatures below indicate acceptance that the equipment or project is safe and satisfactory to start-up with the exceptions noted.Engineering / MaintenanceDateEHS GroupDateQA GroupDateManufacturing / OperationsDateProject EngineerDateProcess EngineeringDateChecklistItem No.Det

25、ails (reference category/item no.)ResponsibilityCompleteSign & DateCategory AAction Items - Items to be completed BEFORE authorization and start-upCategory B Action Items - Items to be completed AFTER start-upSign below only whenall punch list “before start-up items are completedAuthorized:Facility/

26、Equipment Owner Signature:DatePSSR ITEM NO.CATEGORY/ITEM TO ASSESSNotApplicable1.1GENERAL SAFETY1.1.1Have ALL appropriatepersonnel (Operations, Maintenance, Technical, and Supervision) received adequate and appropriate training on the equipment and operating procedures?1.1.2Has adequate and appropri

27、ate PPE (Personal Protective Equipment) been specified in the Work Procedures and/or Standard Operating Procedures. Has the PPE been provided?Have the PPE users been trained in the use of the PPE? Is the training documented?1.1.3Have measures been taken to adequately guard all dangerous parts of thi

28、s equipment? 1.1.4Has sufficient provision been made for the electrical and/or mechanical isolation of the equipment?1.1.5Are points of isolation clearly marked/labeled and readily accessible?1.1.6Have bump/trip hazards been properly identified and adequately marked? Have all sharp edges been remove

29、d?1.1.7Has proper guarding, handrails/barriers, been provided to prevent falls?1.1.8Have all hot/cold surfaces been adequately guarded to prevent burns? Are all cold surfaces adequately insulated to prevent condensation drips (slip hazards)?1.1.9Are Safety Showers and EyeWash facilities provided and

30、 adequately marked? Are the Safety Showers and EyeWash facilities routinely inspected?Do the Safety Showers and EyeWash facilities locations comply with Corporate guidelines?Are the Safety Showers and EyeWash facilities readily visible and accessible? 1.1.10Has sufficient lighting been provided so t

31、hat operation, servicing, maintenance, and repair of the facilities can be carried out safely?1.1.11Are 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 r

32、ead? 1.1.12Have 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?1.1.13Are all of the applicable Work Permit Procedures (Confined Space Entry, Lock Out/Tag Out, Hot W

33、ork, High Work, etc.) in place? Have the Operating, Maintenance, and Supervisory personnel been properly trained on the Work Permit Procedures? 1.1.14Has the fire protection systems been inspected by the insurance company?Has acceptance testing been completed and documented?Is there an agreed on tes

34、t and inspection program for the fire protection systems (including alarm systems)?1.2MACHINERY/EQUIPMENT SAFETY1.2.1Has the machinery/equipment been installed so that it will be stable and secure during operation?1.2.2Has all access to dangerous moving parts, or danger zones created by the equipmen

35、t, been prevented by the provision of the correct guards, interlocks (both safety & non-safety) and/or barriers?1.2.3Have 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?1.2.4Has safe acces

36、s been provided to the equipment that requires operator and calibration and maintenance personnel access for normal operations, adjustments, service, calibration, maintenance, or repair? Have slip, trip, trap, crush, entanglement, fall, bump, and cut hazards been minimized?1.2.5Is the equipment prov

37、ided with the properly identified START/STOP and EMERGENCY controls that are positioned for safe operation without hesitation, or loss of time, and without ambiguity?1.2.6Is the equipment provided with a clearly identified means to securely isolate it from ALL energy sources?1.3ERGONOMICS1.3.1Have t

38、he 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?1.3.2Has the need to lift, carry, push or pull heavy loads, or parts, been eliminated to the extent possible?

39、1.3.3Are all display screens, dials and START/STOP/ EMERGENCY buttons positioned so that they are readily visible and accessible by the operating personnel?1.3.4Have Visual Display Screens been positioned so that interference from glare is reduced to the minimum?1.3.5Have workstations been designed

40、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.)1.3.6Does the operation of this equipment increase the risk of Upper Limb Disorder; for example, repetitive tasks, handling op

41、erations, machine paced work and prolonged operation?1.4OCCUPATIONAL HEALTH1.4.1Have all health risks arising from the gases, liquids, dusts, mists, biological hazards or vapors used by, contained in or emitted by this equipment been assessed?Have the health risks been eliminated or are adequate eng

42、ineering controls utilized to minimize the risks?1.4.2Has adequate RPE (Respiratory Protective Equipment) been specified in the Operating Procedures?1.4.3Has the need for an Occupational Health Monitoring Programme been assessed?Has a Monitoring Programme been scheduled?1.4.4Have the Operating Proce

43、dures been reviewed to take into account any additional “health hazards which may arise from operation or maintenance of this equipment?1.4.5Has adequate LEV (Local Exhaust Ventilation) been installed, tested, balanced, and entered on an Inspection Schedule? 1.4.6Have adequate inspection/cleaning po

44、rts been provided on ductwork?1.4.7Are relief facilities directed to a safe place away from the workplace?1.4.8Has a Noise Survey been considered and a Noise Compliance Plan prepared, if required?1.4.9Has all insulation been identified? 1.4.10Has all pipe work, tanks, and equipment containing hazard

45、ous materials been adequately labeled?2.0PROCESS SAFETY2.1PROCESS TECHNOLOGY2.1.1Are up-to-date Material Safety Data Sheets available?2.1.2Have the hazardous effects of inadvertent mixing of different materials been considered (that is, has a chemical interaction matrix been prepared/updated)? 2.1.3

46、Has the process design basis been documented or updated?Has the control philosophy and sequence of operations been documented?2.1.4Has the equipment design basis (for example, BPFs/P&IDs) been documented/updated?2.1.5Have the recommendations from safety reviews, Process Hazards Analysis (PHA), Hazar

47、ds and Operability Reviews (HAZOP), CHAZOP, or others, been implemented? Record any incomplete items.2.1.6Are all relief devices shown on the P&IDs?Are standard markings used on the relief devices?Are the relief/rupture pressures included on the P&IDs?2.1.7Have the pressure relief device calculation

48、s been provided?Was DIERS technology utilized to size the pressure relief devices for all pressure vessels?Does the sizing of pressure relief devices agreed with the calculated sizes?Do the calculations take into the downstream piping?2.1.8Do the relief devices vent to safe locations?Is containment

49、provided for liquids and solids released from pressure relief devices?2.1.9Are there isolation valves that, if closed, will inhibit the operation of pressure relief devices?If yes, Operations must establish control plans to insure that the isolation valves cannot inhibit the operation of the pressur

50、e relief devices.2.1.10Are all pressure relief devices included in the Preventive Maintenance Program? Are the inspection and testing of relief devices in accordance with local regulations?2.2MANAGEMENT OF CHANGE TECHNOLOGY/MANAGEMENT OF SUBTLE CHANGE2.2.1Has a management of change technology/subtle

51、 change document (for example, Change of Design - COD) been approved?2.2.2Has a test authorization been approved?2.2.3Are all action items, arising from the COD, that were deemed necessary for start-up, complete? 2.2.4Have all changes made during construction been recorded and authorized? Have hazar

52、ds evaluations (PHAs, HAZOP, or CHAZOP) been done on all the changes made during construction?2.3PROCESS HAZARDS ANALYSIS2.3.1Have project PHAs been approved and a final project safety report been prepared?2.3.2Are all action items, deemed necessary by the PHA team for start-up, complete?2.3.3Has th

53、e project been approved as “Safe to proceed with by the PHA team?2.4QUALITY ASSURANCE2.4.1Have checks and inspections been made to ensure that critical equipment is installed properly and is consistent with design specifications and vendors recommendations (for example, alarm and interlock (safety &

54、 non-safety) tests; equipment alignment and service to process inter-connections)?2.4.2Have quality assurance inspection reports, covering fabrication, assembly, and installation, been completed in accordance with the projects quality assurance plan and reports filed with the equipment and design ba

55、sis documentation?2.4.3List specific items field checked as part of this Pre-Start-up Safety Review to ensure that:The construction meets the design specifications.The construction matches the drawings.2.4.4Have the following documented been provided and approved: Instrument indexes and instrument l

56、oop diagrams?A tabulation, including settings, of interlocks (both safety & non-safety) and trips (hardwire and software), process alarms and permissive descriptions?As-built drawings covering P&IDs, electrical, piping, and mechanical?Data sheets for pressure equipment built to ASME or equivalent co

57、des?Welder certification?Non-destructive test (NDT) certifications?Electrical certification for classified areas? 2.5MECHANICAL INTEGRITY2.5.1Have maintenance procedures been approved?2.5.2Have maintenance personnel been trained?2.5.3Have spare parts listed been developed and entered into the parts

58、ordering software program?Are there adequate inventories of spare parts, operating supplies and maintenance materials?2.5.3Have quality control procedures been approved for maintenance materials and spare parts?2.5.4Have inspections and tests, including regulatory requirements) for the following equ

59、ipment been included in a maintenance schedule?Pressure vessels and storage tanks?Pressure relief systems, vent systems, and devices?Critical controls, interlocks (both safety & non-safety), alarms and instruments?Emergency devices (including shutdown systems and isolation systems)?Fire protection e

60、quipment?Piping systems (incl. Components, for example, valves, excess flow valves, expansion bellows) in critical service?Key process-to-service tie-ins?Electrical earthening, grounding, bonding?MCC starters?Emergency alarm and communication system?Monitoring devices and sensors?Pumps?Lifting equip