化工廠常用PSSR檢查表國(guó)外

（能源化工行業(yè)）化工廠常用PSSR檢查表國(guó)外PSSRChecklistExampleA-1PSSR清單示例A-1DescriptionofSystem/AreaUnderReviewDateTime所審查系統(tǒng)/區(qū)域的描述日期時(shí)間ListofParticipantsCirculation:thosepresentplus…參與者名單傳閱：參加人員加上Comments討論ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）1.ReviewHAZOPlistforapplicableactions查看HAZOP列表看相關(guān)行動(dòng)項(xiàng)是否解決2.ReviewCHAZOPlistforapplicableactions查看CHAZOP列表看相關(guān)行動(dòng)項(xiàng)是否解決3.Reviewpunchlistforapplicableactions.查看剩余工作清單看相關(guān)行動(dòng)項(xiàng)是否解決4.Noiselevelmonitoring(document)噪音等級(jí)監(jiān)測(cè)（文件）5.Exposuremonitoring(document)操作人員暴露風(fēng)險(xiǎn)監(jiān)測(cè)（文件）6.Emissionspermits排放許可7.Otheroperatingpermits其他允許的行動(dòng)SystemCheckoutItems系統(tǒng)檢查項(xiàng)目ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）8.Complete/documentqualityassuranceprogram:完成質(zhì)量保證體系并建立了文檔a)Receivedequipment=purchased收到的設(shè)備=購(gòu)買的設(shè)備b)Adherencetodesigndrawings/specifications采用的設(shè)計(jì)規(guī)范c)Materialsofconstruction施工材料d)Workmanship工藝技術(shù).Equipmentcomponentscheckout/commissioning(document)設(shè)備部件檢查/調(diào)試（文件）9.Loopandinterlock/permissive/alarm:setpointadjustmentandtesting(documentresults)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）10.Instrumentcalibrationsdoneanddocumented儀表校訂完成并記錄11.Validationprotocoldeveloped,approvedandexecuted制定、批準(zhǔn)和執(zhí)行的驗(yàn)證協(xié)議12.Pressuretestingdoneanddocumented壓力測(cè)試完成并記錄13.Systemcleanedandflushed系統(tǒng)已完成清掃、沖洗14.Fireprotectionssystemsinspected,acceptance-testeddocumentationprovided消防系統(tǒng)已檢查，并有測(cè)試、驗(yàn)收記錄15.Ventilationsystemsbalanced通風(fēng)系統(tǒng)已平衡16.Performancecheckoutoflocalexhaustsystems局部排氣系統(tǒng)的性能檢測(cè)ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）17.Vibrationmeasurements/documentation振動(dòng)測(cè)量記錄18.Fieldradiographydoneanddocumentedasrequired現(xiàn)場(chǎng)放射性物質(zhì)檢測(cè)已完成并記錄19.Baselinedata,suchasthicknessreadingsforpressurevessels/piping基礎(chǔ)數(shù)據(jù)，如壓力容器/管線的壁厚20.Otherbaselinedata其他基礎(chǔ)數(shù)據(jù)21.NDTreports無(wú)損檢測(cè)報(bào)告22.Waterbatching(document)配水（記錄）EngineeringDesignDocumentation工程設(shè)計(jì)資料23.Narrativeofcontrolphilosophy/Sequenceofoperationsdocumentation操作控制原理/操作順序的說(shuō)明資料24.Instrumentindex儀表索引25.Instrumentloopdiagrams儀表回路圖26.Interlock(safety&non-safety)descriptions聯(lián)鎖（安全和非安全）描述27.As-builtdrawings:P&IDs,electrical,piping,mechanical竣工圖：P＆ID圖，電氣圖，配管圖，機(jī)械圖28.Tabulationofprocessalarms,interlocks/permissivedescriptionsandtripswithsettings(P&ID)工藝報(bào)警表、聯(lián)鎖/許可說(shuō)明表和帶設(shè)定值(P&ID)的跳轉(zhuǎn)表29.Reviewandapprovaloffireprotectionssystemsdesign消防系統(tǒng)設(shè)計(jì)的審查和許可ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）30.Pipingspecifications(P&I/mechanicaldrawings)配管圖（P＆I圖/機(jī)械圖）31.Pressurereliefdevicesizingcalculations安全閥規(guī)格的選定計(jì)算32.ASMEcodepressurevesselsU-1datasheets(toMaintenance)壓力容器ASME代碼U-1數(shù)據(jù)表（用于維修）33.Referencecodes/standardsforfacilitydesign裝置設(shè)計(jì)的參考規(guī)范/標(biāo)準(zhǔn)34.Referencecodes/standardsforfacilityinstallation設(shè)備安裝的參考規(guī)范/標(biāo)準(zhǔn)35.Designcodesforspecificequipment特殊設(shè)備的設(shè)計(jì)規(guī)范36.Weldercertification焊工資格證書(shū)37.NDTcertification無(wú)損檢測(cè)證書(shū)38.Electricalclassificationdrawings電器分類圖39.Electriciancertificationforclassifiedareas特定施工區(qū)域的電工資格證書(shū)MaintenanceItems維修項(xiàng)目40.SparepartslistsdevelopedListequipment:備品備件清單并附設(shè)備清單41.Stockrequiredspareparts備品備件所需儲(chǔ)存設(shè)施42.Equipmentmanuals/specificationstoMaintenanceandOperatingDepartment維修和操作部門的設(shè)備手冊(cè)/說(shuō)明43.Vendorprints供應(yīng)商提供的印刷資料ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）44.Submitpreventivemaintenancerequests(PM’s)提交的預(yù)防性維修要求45.Servicecontractsinplace服務(wù)合同已簽訂46.Trainmaintenancepersonnelanddocument培訓(xùn)維修人員和相關(guān)培訓(xùn)資料OperationalItems生產(chǎn)項(xiàng)目47.DevelopSOPandspecialprocedures–incorporatesafetyandoperationalissues:編寫(xiě)標(biāo)準(zhǔn)操作規(guī)程（SOP）及特殊操作規(guī)程——考慮了操作風(fēng)險(xiǎn)和可操作性問(wèn)題48.Completechangecontrolauthorizations完成變更控制授權(quán)49.Develop/issueoperatingprocedures:制定/頒布下列操作規(guī)程a)Initialstart-up初次開(kāi)車b)Normalstart-up正常開(kāi)車c)Normaloperation正常操作d)Normalshutdown正常停車e)Emergencyoperationsincludingemergencyshutdown包括緊急停車的應(yīng)急操作f)Start-upfollowingemergencyshutdown緊急停車后開(kāi)車g)Start-upfollowingturnaround大修后開(kāi)車h)Non-routineprocedures(equipmentclean-out,equipmentpreparationformaintenance)非常規(guī)程序（設(shè)備清理、設(shè)備維修準(zhǔn)備）ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）i)Auxiliaryequipmentoperation輔助設(shè)備的操作50.Trainoperatingpersonnelanddocument培訓(xùn)操作人員和相關(guān)培訓(xùn)資料51.Providetechnicalcoverage技術(shù)服務(wù)范圍52.Whatistheprobabilityofcontainmentfailure?Whatarethesubsequentconsequences?Reviewspillcontainment,rainwaterrunoff,andfirewatercontainment.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ElectricalIssues電氣問(wèn)題53.Panelaccess,clearancearoundpanel,keys,etc.配電盤的通道、配電盤周圍的間隙、鑰匙等54.Cableentrysection–glanding,housekeepingandotherissues電纜接入部分—密封、保潔及其他問(wèn)題55.Panelpowersourceidentified?Multiplefeeds?配電盤電源的標(biāo)識(shí)？多源供電？56.Spaceheatersrequired?需要空間加熱器嗎？57.Lightinginpanels配電盤里的照明58.Canopiesetc.foroutdoorpanels用于室外配電盤的雨棚等59.Protectionsettingsavailable?有保護(hù)設(shè)置嗎？60.Panelboardschedules配電盤面板清單61.Sparecapacityavailable?有備用容量嗎？62.PPEavailable?HVmats,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?ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）63.Emergency/Standbypowerrequired?有應(yīng)急/備用電源嗎？64.VSDsettingsavailable–factory/commissioning變頻器設(shè)置—工廠/調(diào)試65.Roomaccess,permitting,maintainability,ingress/egressofequipment房間通道、許可證、可維修性、設(shè)備的進(jìn)出通道66.Pocketsfordrawingsinpanels?配電盤的圖紙集67.Voltagewarninglabels?電壓警告標(biāo)簽68.Ventilationsufficient?通風(fēng)充足嗎？69.Suitabilityforarea-IPrating,GMPsuitability,hazardousareaclassification.區(qū)域適宜性——國(guó)際防護(hù)等級(jí)、GMP適宜性、危險(xiǎn)區(qū)域分類-ReliefDevices-泄放設(shè)備70.AretherestandardmarkingsontheP&ID?在P&ID圖上有標(biāo)準(zhǔn)代號(hào)嗎？71.Dorelieflinesventtoasafelocation?放空線排放到一個(gè)安全地點(diǎn)嗎？72.Arerelieflinesandreliefdevicessecuredandadequatelysized?放空線和泄放設(shè)備安全嗎?尺寸足夠大嗎？73.Arethereanyisolationvalveswhichwillinhibitoperationofreliefvalvesifclosed?IfYES,nominateOperationstomonitor.IfNO,recordno.有處于關(guān)閉狀態(tài)會(huì)抑制放空閥操作的隔離閥嗎？如果有，請(qǐng)指定操作人員對(duì)其進(jìn)行監(jiān)視。如果沒(méi)有，記錄無(wú)ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）74.Isthereastandardoperatingprocedureforreliefdevicesinplace?現(xiàn)場(chǎng)有泄放設(shè)備的標(biāo)準(zhǔn)操作規(guī)程嗎？-ForFieldVerification-現(xiàn)場(chǎng)確認(rèn)75.Islightingsufficient?照明充足嗎？76.Isemergencylightingsufficient?應(yīng)急照明充足嗎？77.Aresteampipes,valves,ortrapssituatedwithinproximityofpeopleinsulated?位于人接近范圍內(nèi)的蒸汽管線、閥門或疏水器被隔離了嗎？78.Isallinstrumentationidentifiedandtagged?所有的儀表都有標(biāo)識(shí)和掛牌了嗎？79.Isthereanyrustedordamagedequipment?有任何生銹或損壞的設(shè)備嗎？80.Areswinggatesinstalledontopofladdersoronaccessplatforms?在梯子頂部或平臺(tái)通道上安裝了止回門嗎？81.Reviewedgeprotectiononplatformsandheights.Willitprotectpersonnelandequipment?Isaccessadequate?檢查平臺(tái)和高處的邊緣保護(hù)。它能保護(hù)人員和設(shè)備嗎？通道足夠嗎？82.Dosafetyshowersprovideahazardtopeople(slips),product(contaminationofsystems),oringresstoelectricalswitchgearorequipment?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(kāi)關(guān)柜或設(shè)備產(chǎn)生危險(xiǎn)了嗎？83.Aresafetyshowerssuppliedfromtemperedwater?安全淋浴供應(yīng)熱水嗎？84.Ischemicaldosingwithinasafeproximityofpeopleandproduct?化學(xué)品操作是在人和產(chǎn)品安全接近范圍內(nèi)嗎？ItemRecommendationDepartment/CompletedResponsibleNo.(TypeActionBelowor‘notDateapplicable’)Person序號(hào)完成日期建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適部門/責(zé)任人用”）85.Labelallpipelines標(biāo)識(shí)所有的管線86.Labelallelectricswitches,disconnects,MCCs,controlpanels,cables,etc.標(biāo)記所有的電氣開(kāi)關(guān)、中斷器、電動(dòng)機(jī)控制器、控制盤和電纜87.Labelvessels(material,hazardwarnings)List:標(biāo)記容器（材料、危險(xiǎn)警告）的清單88.Sealwallpenetrations密封墻壁的滲透89.Pourconduitseals灌注導(dǎo)管的密封90.Installfireextinguishers91.Evacuationroutesposted92.Installappropriateareasigns93.Isallscaffoldingandequipmentremoved;isgeneralhousekeepingacceptable?94.Ifthereispotentialforentrapmentorexposure,hasanE-Stopbeenprovided?95.Iffullguardingisinplace,hasalockableisolationdevicebeenprovided?96.Pestcontrolrequiredinroom/building?97.MSDSsheetsrequired?98.Sprinklersinrooms?99.Singlepointoffailurecondition?Hasitbeenidentified?–Record.PSSRChecklistExampleA-2Pre-startupSafetyReviewChecklistInspectionDate:Department/Area:ProjectNumber:Title/Equipment:Signaturesbelowindicateacceptancethattheequipmentorprojectissafeandsatisfactorytostart-upwiththeexceptionsnoted.Engineering/MaintenanceDateEHSGroupDateQAGroupDateManufacturing/OperationsDateProjectEngineerDateProcessEngineeringDateDetails(referencecategory/itemResponsibilityComplete

Checklistno.)Sign&ItemNo.DateCategoryAActionItems-ItemstobecompletedBEFOREauthorizationandstart-up.5.CategoryBActionItems-ItemstobecompletedAFTERstart-up..2.Signbelowonlywhenallpunchlist“beforestart-up”itemsarecompletedAuthorized:Facility/EquipmentOwnerSignature:DatePSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable1.1GENERALSAFETY1.1.1HaveALLappropriatepersonnel(Operations,Maintenance,Technical,andSupervision)receivedadequateandappropriatetrainingontheequipmentandoperatingprocedures?1.1.2HasadequateandappropriatePPE(PersonalProtectiveEquipment)beenspecifiedintheWorkProceduresand/orStandardOperatingProcedures.HasthePPEbeenprovided?HavethePPEusersbeentrainedintheuseofthePPE?Isthetrainingdocumented?1.1.3Havemeasuresbeentakentoadequatelyguardalldangerouspartsofthisequipment?1.1.4Hassufficientprovisionbeenmadefortheelectricaland/ormechanicalisolationoftheequipment?1.1.5Arepointsofisolationclearlymarked/labeledandreadilyaccessible?1.1.6Havebump/triphazardsbeenproperlyidentifiedandadequatelymarked?Haveallsharpedgesbeenremoved?1.1.7Hasproperguarding,handrails/barriers,beenprovidedtopreventfalls?1.1.8Haveallhot/coldsurfacesbeenadequatelyguardedtopreventburns?Areallcoldsurfacesadequatelyinsulatedtopreventcondensationdrips(sliphazards)?1.1.9AreSafetyShowersandEyeWashfacilitiesprovidedandadequatelymarked?AretheSafetyShowersandEyeWashfacilitiesroutinelyinspected?DotheSafetyShowersandEyeWashfacilitieslocationscomplywithCorporateguidelines?AretheSafetyShowersandEyeWashfacilitiesreadilyvisibleandaccessible?1.1.10Hassufficientlightingbeenprovidedsothatoperation,servicing,maintenance,andrepairofthefacilitiescanbecarriedoutsafely?1.1.11Arenotices,dials,screens,etc.forprovidingoperationalinstructions,safetywarnings,andemergencyinformationprovided,ifrequired,andpositionedsothattheyareclearlyvisibleandeasilyread?PSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable1.1.12Havealloverheadfixtures,forexample,pipe-hangers,pipesleeves,pipesleevecovers,valvehandles,flooropeningcovers,etc.,whichcouldfallorbedislodged,beenproperlysecured?1.1.13ArealloftheapplicableWorkPermitProcedures(ConfinedSpaceEntry,LockOut/TagOut,HotWork,HighWork,etc.)inplace?HavetheOperating,Maintenance,andSupervisorypersonnelbeenproperlytrainedontheWorkPermitProcedures?1.1.14Hasthefireprotectionsystemsbeeninspectedbytheinsurancecompany?Hasacceptancetestingbeencompletedanddocumented?Isthereanagreedontestandinspectionprogramforthefireprotectionsystems(includingalarmsystems)?1.2MACHINERY/EQUIPMENTSAFETY1.2.1Hasthemachinery/equipmentbeeninstalledsothatitwillbestableandsecureduringoperation?1.2.2Hasallaccesstodangerousmovingparts,ordangerzonescreatedbytheequipment,beenpreventedbytheprovisionofthecorrectguards,interlocks(bothsafety&non-safety)and/orbarriers?1.2.3Havethecorrectsafetymeasuresbeentakentopreventanyriskfromhot/coldsurfaces,ejectionofmaterial,failureofpartsandtheirejection,overheating/fire?1.2.4Hassafeaccessbeenprovidedtotheequipmentthatrequiresoperatorandcalibrationandmaintenancepersonnelaccessfornormaloperations,adjustments,service,calibration,maintenance,orrepair?Haveslip,trip,trap,crush,entanglement,fall,bump,andcuthazardsbeenminimized?1.2.5IstheequipmentprovidedwiththeproperlyidentifiedSTART/STOPandEMERGENCYcontrolsthatarepositionedforsafeoperationwithouthesitation,orlossoftime,andwithoutambiguity?1.2.6IstheequipmentprovidedwithaclearlyidentifiedmeanstosecurelyisolateitfromALLenergysources?1.3ERGONOMICS1.3.1Havetheworkstations,workplace,orequipmentbeenconstructedsothatneedforstooping,bendingstretching,over-reachingandworkingover-headduringoperationhasbeeneliminatedorminimized?1.3.2Hastheneedtolift,carry,pushorpullheavyloads,orparts,beeneliminatedtotheextentpossible?PSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable1.3.3Arealldisplayscreens,dialsandSTART/STOP/EMERGENCYbuttonspositionedsothattheyarereadilyvisibleandaccessiblebytheoperatingpersonnel?1.3.4HaveVisualDisplayScreensbeenpositionedsothatinterferencefromglareisreducedtotheminimum?1.3.5Haveworkstationsbeendesignedandequippedsothattheoperatorcanadoptacomfortableposition?(Thatis,abletostand,orchangepositionandsitupright,angleatelbowsandknees90,feetonfloor.)1.3.6DoestheoperationofthisequipmentincreasetheriskofUpperLimbDisorder;forexample,repetitivetasks,handlingoperations,machinepacedworkandprolongedoperation?1.4OCCUPATIONALHEALTH1.4.1Haveallhealthrisksarisingfromthegases,liquids,dusts,mists,biologicalhazardsorvaporsusedby,containedinoremittedbythisequipmentbeenassessed?Havethehealthrisksbeeneliminatedorareadequateengineeringcontrolsutilizedtominimizetherisks?1.4.2HasadequateRPE(RespiratoryProtectiveEquipment)beenspecifiedintheOperatingProcedures?1.4.3HastheneedforanOccupationalHealthMonitoringProgrammebeenassessed?HasaMonitoringProgrammebeenscheduled?1.4.4HavetheOperatingProceduresbeenreviewedtotakeintoaccountanyadditional“healthhazards”whichmayarisefromoperationormaintenanceofthisequipment?1.4.5HasadequateLEV(LocalExhaustVentilation)beeninstalled,tested,balanced,andenteredonanInspectionSchedule?1.4.6Haveadequateinspection/cleaningportsbeenprovidedonductwork?1.4.7Arerelieffacilitiesdirectedtoasafeplaceawayfromtheworkplace?1.4.8HasaNoiseSurveybeenconsideredandaNoiseCompliancePlanprepared,ifrequired?1.4.9Hasallinsulationbeenidentified?1.4.10Hasallpipework,tanks,andequipmentcontaininghazardousmaterialsbeenadequatelylabeled?2.0PROCESSSAFETY2.1PROCESSTECHNOLOGY2.1.1Areup-to-dateMaterialSafetyDataSheetsavailable?PSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable2.1.2Havethehazardouseffectsofinadvertentmixingofdifferentmaterialsbeenconsidered(thatis,hasachemicalinteractionmatrixbeenprepared/updated)?2.1.3Hastheprocessdesignbasisbeendocumentedorupdated?Hasthecontrolphilosophyandsequenceofoperationsbeendocumented?2.1.4Hastheequipmentdesignbasis(forexample,BPF’s/P&IDs)beendocumented/updated?2.1.5Havetherecommendationsfromsafetyreviews,ProcessHazardsAnalysis(PHA),HazardsandOperabilityReviews(HAZOP),CHAZOP,orothers,beenimplemented?Recordanyincompleteitems.2.1.6AreallreliefdevicesshownontheP&IDs?Arestandardmarkingsusedonthereliefdevices?Aretherelief/rupturepressuresincludedontheP&IDs?2.1.7Havethepressurereliefdevicecalculationsbeenprovided?WasDIERStechnologyutilizedtosizethepressurereliefdevicesforallpressurevessels?Doesthesizingofpressurereliefdevicesagreedwiththecalculatedsizes?Dothecalculationstakeintothedownstreampiping?2.1.8Dothereliefdevicesventtosafelocations?Iscontainmentprovidedforliquidsandsolidsreleasedfrompressurereliefdevices?2.1.9Arethereisolationvalvesthat,ifclosed,willinhibittheoperationofpressurereliefdevices?Ifyes,Operationsmustestablishcontrolplanstoinsurethattheisolationvalvescannotinhibittheoperationofthepressurereliefdevices.2.1.10AreallpressurereliefdevicesincludedinthePreventiveMaintenanceProgram?Aretheinspectionandtestingofreliefdevicesinaccordancewithlocalregulations?2.2MANAGEMENTOFCHANGE–TECHNOLOGY/MANAGEMENTOFSUBTLECHANGE2.2.1Hasamanagementofchange–technology/subtlechangedocument(forexample,ChangeofDesign-COD)beenapproved?2.2.2Hasatestauthorizationbeenapproved?2.2.3Areallactionitems,arisingfromtheCOD,thatweredeemednecessaryforstart-up,complete?PSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable2.2.4Haveallchangesmadeduringconstructionbeenrecordedandauthorized?Havehazardsevaluations(PHAs,HAZOP,orCHAZOP)beendoneonallthechangesmadeduringconstruction?2.3PROCESSHAZARDSANALYSIS2.3.1HaveprojectPHAsbeenapprovedandafinalprojectsafetyreportbeenprepared?2.3.2Areallactionitems,deemednecessarybythePHAteamforstart-up,complete?2.3.3Hastheprojectbeenapprovedas“Safetoproceedwith”bythePHAteam?2.4QUALITYASSURANCE2.4.1Havechecksandinspectionsbeenmadetoensurethatcriticalequipmentisinstalledproperlyandisconsistentwithdesignspecificationsandvendor’srecommendations(forexample,alarmandinterlock(safety&non-safety)tests;equipmentalignmentandservicetoprocessinter-connections)?2.4.2Havequalityassuranceinspectionreports,coveringfabrication,assembly,andinstallation,beencompletedinaccordancewiththeproject’squalityassuranceplanandreportsfiledwiththeequipmentanddesignbasisdocumentation?2.4.3ListspecificitemsfieldcheckedaspartofthisPre-Start-upSafetyReviewtoensurethat:Theconstructionmeetsthedesignspecifications.Theconstructionmatchesthedrawings.2.4.4Havethefollowingdocumentedbeenprovidedandapproved:Instrumentindexesandinstrumentloopdiagrams?Atabulation,includingsettings,ofinterlocks(bothsafety&non-safety)andtrips(hardwireandsoftware),processalarmsandpermissivedescriptions?As-builtdrawingscoveringP&IDs,electrical,piping,andmechanical?DatasheetsforpressureequipmentbuilttoASMEorequivalentcodes?Weldercertification?Non-destructivetest(NDT)certifications?Electricalcertificationforclassifiedareas?2.5MECHANICALINTEGRITY2.5.1Havemaintenanceproceduresbeenapproved?2.5.2Havemaintenancepersonnelbeentrained?PSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable2.5.3Havesparepartslistedbeendevelopedandenteredintothepartsorderingsoftwareprogram?Arethereadequateinventoriesofspareparts,operatingsuppliesandmaintenancematerials?2.5.3Havequalitycontrolproceduresbeenapprovedformaintenancematerialsandspareparts?2.5.4Haveinspectionsandtests,includingregulatoryrequirements)forthefollowingequipmentbeenincludedinamaintenanceschedule?Pressurevesselsandstoragetanks?Pressurereliefsystems,ventsystems,anddevices?Criticalcontrols,interlocks(bothsafety&non-safety),alarmsandinstruments?Emergencydevices(includingshutdownsystemsandisolationsystems)?Fireprotectionequipment?Pipingsystems(incl.Components,forexample,valves,excessflowvalves,expansionbellows)incriticalservice?Keyprocess-to-servicetie-ins?Electricalearthening,grounding,bonding?MCCstarters?Emergencyalarmandcommunicationsystem?Monitoringdevicesandsensors?Pumps?Liftingequipment?2.5.5Hasareliabilityengineeringanalysisbeenconsidered/completedforPSMcriticalequipment?2.5.6Istheequipmentinspectedbyanyoutsidebodyandcertificatesonfile(forexample,CEmarking,liftingequipmenttestcertificates,pressuresystemsregulations,andotheritems)?2.5.7Haveallcommissioningtestsorinspectionsbeenidentified(forexample,pressure,orleaktests,passivatingprocedures)?2.6OPERATINGPROCEDURESANDSAFEWORKPRACTICES2.6.1Havestandardoperatingproceduresbeenprepared/updatedandapproved?Dotheoperatingprocedurescover:PSSRITEMCATEGORY/ITEMTOASSESSNotNO.ApplicableInitialstart-up?Normalstart-up?Normaloperations?Normalshutdowns?Emergencyoperationsincludingemergencyshutdowns?Start-upafteremergencyshutdowns?Start-upfollowingturnarounds/prolongedshutdowns?Non-routineproceduresuchasequipmentclean-outsandpreparationofequipmentformaintenance?Auxiliaryequipmentoperationsincludingasexamples;LEVandVentilationSystems,Heat/CoolSkids,Water(Soft,RO,WFI,Tower,etc.)Systems,InstrumentandProcessAirSystems,WasteTreatmentSystems,Cooling(GlycolRefrigeration)Systems,SteamGeneration,andothers?Safetyandoperationalissues?Changecontrolprocedures?2.7TRAININGANDPERFORMANCE2.7.1Hasspecificprocess(orjobtask)trainingbeengiventopersonnel?2.7.2.Havetrainingrecordsbeenupdated?2.8CONTRACTORSAFETY2.8.1.Haveallcontractpersonnelbeenadequatelytrainedinappropriate:chemicalawareness,maintenance,andoperatingactivitiesandevacuationprocedures?2.9INTERLOCKSANDALARMS2.9.1Hasthealarm/interlock(safety&non-safety)beenclassifiedanddesignedbytheProjectTeam?DidtheProjectTeamincludemembersofthePHAteam?2.9.2Didthelooptestingconfirmthatthealarm/interlock(safety&non-safety)actionproved,underallconceivablefailureconditions,tobefail-safe?2.9.3.PriortothisPSSR,hasaninterlock/criticalalarmStandardOperatingProcedurefortesting,throughtothefinalelement,beenpreparedandreviewed/authorizedbyacompetentpersonforeachneworupgradedcontrolsystem?2.9.4.Foralarms/interlocks(bothsafety&non-safety)withmorethanonesoftwareorhardwarecircuit,haveallpossibleinterlockroutesbeentested?2.9.5Hasallappropriateprocesstechnologybeenupdated(forexample,interlocklists,P&IDs,logicdrawings,etc.)?2.9.6DoesyourControlSystemdocumentationadequatelyspecify:PSSRITEMCATEGORY/ITEMTOASSESSNotNO.ApplicableAllmajorcomponentsandtheirmodelandserialnumbers?Allcommunicationcableslayoutandconfiguration?Anyconfigurableorcustomsettingsandset-up?2.9.7Hasconsiderationbeengiventosuitablefiredetectionandpreventionsystemsfortheequipment?2.9.8Doyouhaveanappropriateproceduretoensurethatyoursoftwareisprotected(forexample,routinelyarchived,key/passwordprotected,etc.)?2.9.9Hasthesoftwarebeenproperlydocumentedandfiled(forexample,logicdrawings,schematics,sequence/batchdescriptions)?2.9.10Hasallsoftwarebeenproperlyvalidatedandtested?2.9.11Isthereverificationthattheequipmentdoesnotre-start,eitheronthere-settingofaprotectivedevicesuchasaninterlock(safety&non-safety),orthere-establishmentofpowerafteranoutage?3.0ENVIRONMENTAL3.1Areallsecondarycontainment/bondingfacilitiesadequate?3.2Areallmaterialstoragefacilitiesadequateandappropriatelylabeled?3.3Haveadequatearrangementsbeenmade,priortostart-up,fortheidentification,classification,andsafedisposalofallwastematerials?3.4Haveallmaterials,usedinthesystem,beenenteredontheAreaChemicalsInventoryList(orequivalent)?3.5AreupdatedAreaSpillProceduresavailable?3.6ArematerialUnloadingFacilitiesadequateandconstructedinaccordancewithCorporateSafety,Health,andEnvironmentalStandards?Isthereadequatecontainment(110%oftruckvolume)intheunloadingareasforbulkliquidchemicals?3.7HavetheCorporateEnvironmentalGuidelinesbeenfollowedduringthedesignstageofthisproject?3.8Haveallwastestreamsbeenidentified,quantified,analyzedandminimized?3.9ArealloftheapplicableConstruction,EnvironmentalandOperatingPermitsupto-dateandapproved?4.0CAER4.1Haveallnecessaryprecautionsbeentakentoensurethattheequipmentisnotasourceofignitiontoanyflammablematerials,irrespectiveoftheirsource?PSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable4.2Arefireprotectionfacilitiesadequateforexample,fireextinguishers,firewalls,sprinklersystems,AlarmBoxes,etc.)?4.3AreEmergencyEscapeRoutes,includingladders,adequateandproperlysignposted?4.4Isemergencylightingadequate?4.5IssufficientRespiratoryProtectiveEquipment,suchasEscapeSetsorSelf-ContainedBreathingApparatus(SCBA)available?4.6HaveEmergencyProceduresbeenpreparedandrelevantpersonneltrained?4.7IstheCommunityPaneladvisedofproposednewmajorprojects?5.1HasanElectricalSafetyChecklist(AcceptanceofElectricalInstallations)beencompletedbyacompetentpersonnel?5.2HastheequipmentbeenproperlyinstalledandconstructedtoCorporateguidelinesandlocallegislation,anddoesitmeetanyspecialinstallationrequirementsnotedonthemanufacturer’scertificate?5.3Hasequipmentbeendesignedandpurchasedfortheconditionsunderwhichitwilloperate(forexample,hazardousareas)?5.4Arealllivepartsadequatelyenclosedtopreventaccess?5.5Doesgroundingandbondingcomplywithcorporateandlocalstandards/legislation?5.6Havefusesorcircuitbreakersbeenprovidedwhichwillautomaticallydisconnectthesupply?5.7AreFirstAidStations,singlelinedrawingsandPPErequirementsavailableinMotorControlCenters(MCC),ElectricalControlRooms(ECR)/Sub-stations,asappropriate?5.8Haveallrelevantdocumentationanddrawings(forexample,P&IDs,SLDs,Schematics,equipmentarrangement,I/O,logic,electricalclassificationandPanelScheduledrawings)beenupdatedtoreflectthecurrentinstallation?5.9HaveallnewSub-stationBreakers,MCCisolators,startersorotherappropriateequipmentbeenregisteredontotheSiteInspectionSchedule?5.10Haveanyelectricalcircuits,maderedundantbythisinstallation,beenproperlyD&R’d?6.0FIELDVERIFICATIONPSSRITEMCATEGORY/ITEMTOASSESSNotNO.Applicable6.1Isthenormallightingadequatefornormalandmaintenanceoperations?6.2Isemergencylightingsufficient?6.3Areallhotandcoldsurfaces,whichmaycauseburns,intheproximityofpersonnelinsulated?6.4Areallinstruments,equipmentandpipingadequatelylabeled?6.5Isthereanyrustedand/ordamagedequipment?6.6Areswinggatesorchainsinstalledatthetopofladdersand/oronaccessplatforms?6.7Arethereanygapsbetweenplatformsandequipmentthatcouldcreateafoothazard?6.8Isequipmentandplatformaccessadequate?6.9Dosafetyshowers/eyewashstationscreateahazardtopersonnel(slips),potentialforcontaminationofproduct(entrytoequipment)oringresstoelectricalequipment?6.10Aresafetyshowersandeyewashstationsadequatelymarkedandreadilyvisible?Istheaccesstothesafetyshowersandey