You are on page 1of 15

ATTACHMENT I: PRE START-UP SAFETY REVIEW CHECKLIST 1

Facility Dat
e

Project Name Area Building

Process Safety Information


Physical and hazardous properties of all materials
documented.
Process design basis documented.
Design basis for equipment and safety devices documented
(above communicated to proprietor and filed to be readily
available to operating personnel)
Equipment fabricated and installed according to
specification.
Maintenance procedures and preventive maintenance
program are adequate to ensure mechanical integrity
throughout life of the process including the spares.
Operating procedures, safe practices, safety procedures and
emergency procedures are adequate

Training programs are in place for operators and mechanics.

Management of Change procedures to be used for all


changes.
Process hazards analysis/process hazards review
completed and recommended actions completed
Emergency plan based on consequence analysis (people
trained)

Incident Investigation and Reporting Procedure in place

Procedure in place for interaction with contractors in the


area ____________________
Equipment design database updated after new _
equipment installation
Pre-start-up Safety Team Members:
Unit /
Participation Name Designation Department Signature Date
Section
Team Leader

Member Production
Member HSE
Member Maintenance
Member TSD Project
Member TSD Inspection
Member TSD Process
Member E&I Electrical
Member E&I Instrument
Note: PSI section has to be filled before the field audit and summary posted on Attachment IA.
ATTACHMENT IA: PRESTART-UP SAFETY REVIEW
RECOMMENDATIONS

Recommendations to Be Responsibilit
Target
Completed Before Start-up y

Team Leader

Name

Designation

Date

Area In charge

Dated:
ATTACHMENT 2: PRE START-UP SAFETY REVIEW CHECKLIST 2

Title

Project No. Inspected By

Equipment No.

Area / Building.

Date of Inspection

Process Information

Process Material Name


Process Material Hazards

Operation Temperature Operating Pressure


Electrical Classification

Temp- Reqd
Category N/A OK Remarks
orary for S/U
Documentation Items
Is HSE Documentation Complete
& Approved?
Venting Permission Approval in
Place.
Do Not Touch Exception
Required.
Test Authorization available

P&Is Available

Design Documentation Complete


Process hazards Review Required
and Completed Prior to Start-up?
PHR / process Hazards Analysis
Start-up Recommendations
Completed?
Piping and Equipment

Proper Piping and Flanges.


Category N/A OK Temp- Reqd Remarks
orary for S/U
Correct Gaskets / Bolting.

Supports / Vibration.
Correct Insulation for Intended
Service.
Tracing Completed. Tagged &
Identified.
Isolation Valves/Handles

Stored Energy Sources Identified.


Low Point Drains, Flushes, Purge
Connections Adequate For
Maintenance.
Process/Service Connections
Correct
Pressure/Hydro Test Completed.
Relief Device Installed/Directed
Properly Record Updated.
Shielding (Flanges, Valves)
provided if Required.
3-Way Valve Orientation.

Correct Materials of Construction.

Critical Service Documentation.


Makeshift Devices Eliminated,
(Extension Cords, Ropes, Hoses
etc).
Nitrogen Piping Standards
Followed.
Instrumentation: Instrument Loop
Drawing Updated.
Pressure Gauges as Required.

Temperature Gauges as Required.

Fail Safe Valve Position.

Loop Check Completed.

Analyzer Check Completed.

Spare Parts Available.


Equipment Meets the Process
Material Requirements.
Category N/A OK Temp- Reqd Remarks
orary for S/U
DCS Process Control Change
authorization Available.
Guards Installed.
Lubrication and Alignment
Complete.
Emergency Facilities.

Correct Rotation.

P. M. Records in Place.

Spare Parts Available.


Hydraulic Systems Installed Per
Design and Checked Prior to Start-
up.
Electrical Hazards
Conformance to Hazard
Classification.
Grounding, Bonding/Lighting
(Surge) Protection.
Safety or Process Interlocks/
Alarms.
Out of Service Equipment, De-
energized.
Electrical Inspection Complete.
Emergency Switches Required?
Conduits and Boxes Sealed?
Evacuation Alarms Available?

P. M. Records in Place.

Structures
Doors Ramps Fire Doors,
Walls.
Exits (Traffic Flow, Door Swings,
Emergency Escape).
Safety Chains/Handrails/Guard
Rails.
Walkways, Ladders, Stairs.

Floor Drainage/Curbs/Dikes.

Overhead Hazards Removed.


Temp- Reqd
Category N/A OK Remarks
orary for S/U
Operations/Maintenance Platforms
Provided Where Needed.
Procedures

Equipment Description.

Alarms & Instrument Checks.

Alarms & Instrument Listing.

Analyzer Maintenance/ Calibration.

Equipment Guards.

Maintenance.

Building Safety Instructions.

Operating (SOPs).

Spill Control.

Emergency Handling Procedures.

MSDS Approved.

Labeling

NFPA-704 HAZ COM Provided.

Flow Direction.
Instrument (Transmitters, Gauges,
Panel boards, DCS).
Electrical (Switches, MCCs
Buttons, Local Disconnects).
Hi Voltages Labeled?

Hot Surfaces Marked?


Equipment (Tanks, Pumps,
Condensers, Exchangers,
Feeders, Monorails, Hoists, etc.).
Do Not Touch Labels

Other (Nitrogen, Air).

General Items

Temp- Reqd
Category N/A OK Remarks
orary for S/U
Accessibility for Maintenance/
Operations.
Lockout/Tagout Provisions in
Place, Training Complete.
Any Tripping Hazards or Pinch
Points.
Spill Containment Facilities.
Fire Protn Equipment/Sprinklers
Extinguishers, Procedures
Updated.
Safety Shower/Eye Washes
Procedures Updated.
Painting/Safety Painting.

Safety Rules or Signs Installed.


Area and Spot Ventilation
Adequate.
Noise Level Measured.
Lighting Adequate/Emergency
Lights Adequate.
Special Operating Tools Provided
Where Needed.
Equipment Run-in.
Hidden/Stored Energy Sources
Identified?
Mechanical/Contractor Cleaned up
Area.
Training.
Employee Communication
Prepared.

Title
Project No. Date

Deficiencies to be corrected Before Responsibility Target


Startup

Deficiencies correction Not Required


Before Startup Responsibility Target

Deficiencies correction Not Required


Before Startup Responsibility Target

Unit /
Participation Name Designation Department Signature Date
Section
Team Leader

Member Production
Member HSE
Member Maintenance
Member TSD Project
Member TSD Inspection
Member TSD Process
Member E&I Electrical
Member E&I Instrument

ATTACHMENT 3: INSTRUMENT PROJECT AUDIT CHECKLIST


Yes No N/A

JBs Inspection:
1 JB complies with area classification?
2 New JB has a number painted on it.
3 Sealing of the JB door/cover satisfactory for light rain.
4 Lugs properly pressed and terminated.
5 No loose connections. (check a few wires).
Shield not connected at inst. end and is grounded at control
6
system.
7 Proper tagging on all cables with core marker.
JB TBs drawing placed in envelope in JB? (Optional but
8
preferable)
Cables entering JB properly glanded with no opening for
9
dust.
10 On JB's, no top entry for cables.
11 Any spare cable entry points have blind plug.
Segregated AC and DC signals keeping in view voltage
12
levels.
If any shared Inst / Elec signal, has checklist given in I&E
13
proc. been filled.

Control Valve Checks


1 Tag plate installed.
2 Tag name painted.
3 If valve safety critical, is it painted red.
4 Fail-safe position painted on valve? (e.g. A/C or A/O)
5 Close IAS and check valve fail-safe.
6 Block and bleed available for isolation.
Hand jack auto to hand-jack and back to auto procedure
7
displayed?
8 Convenient access exists to hand-jack for operator.

Sov Checks
1 Air bleed port faces down so dust cannot accumulate.
2 Bug-proof installed.
3 No mixed fitting e.g. brass to SS. (If found, rectify)

Cables
1 Cable trays are not overloaded.
2 Fire proofing of the cable trays in the required area done.
3 Cables are away from steam-lines or other heat sources.
4 Distance kept between instrument signal & electrical cables
OTs on conduits have T facing downwards so water does not
5
fill up.

General Field instrumentation:


1 Instruments installed as per area classification.
2 Instruments meet area max. ambient temperature rating ?
If ambient rating near borderline is equipment installed in
3
shade.
4 Location allows easy access for maintenance.
5 Tag plates installed on instruments.
6 Tag name painted onto instrument.
Isolation / depressurization arrangement provided (Block &
7
Bleed)
8 Check IAS supports leading to device are firm and sturdy.
If any spare thermo wells or tapings, plugged and blinded
9
properly?
10 If sq. root required, configure only in DCS, not in transmitter.

Special Instructions to Operator:


Any special procedure to take equipment in service, has
1
been put up?
e.g. If new control-valve with spring loaded glands, pressurize slowly.

Checklist for recording post - commissioning data (reference &


initial observation) has been developed?

Control System:
In Control system (DCS, PLC) cabinet, check terminations
Have new points and schematics been configured and verified.
Have you taken a fresh backup after the changes, irrespective of
backup frequency?
Check for free I/O space on the system, if none inform area
engineer.

Title

Project No. Date

Deficiencies to be corrected Before Responsibility Completed


Startup

Deficiencies correction Not Required


Before Startup Responsibility Target date
Unit /
Participation Name Designation Department Signature Date
Section
Team Leader

Member Production
Member HSE
Member Maintenance
Member TSD Project
Member TSD Inspection
Member TSD Process
Member E&I Electrical
Member E&I Instrument

ATTACHMENT 4: ELECTRICAL PROJECT PSSR CHECKLIST.

Yes No N/A
A) Has I&E Sub-SOC been held for the project (if required)

B) Electrical Single Diagram Updated


C) Under ground Electrical drawing Updated
D) All relevant control schematics updated on CAD
E) In case of MV cable termination or jointing, Box up certificate
obtained
F) In case, any instrument signal coming to Electrical circuit or
vice versa, verification check list as given in I&E procedure is
duly filled
G) In case any protection devices are employed, these are
bench tested & circuit integrity has been checked by a
dummy test from the sensor to final trip element.
H) All isolating breakers have proper lock out and tag out
arrangement
I) Checklist for recording post-commissioning data (Reference
& initial ) has been developed.
J) Area illumination is sufficient.

K) Smoke detectors are installed where required.


L) Air-conditioning is sufficient where required.

JBs / DB's Inspection:


1 JB / DB complies with area classification?
2 New JB / DB has been tagged properly.
3 JB / DB is properly grounded.
4 Sealing of the JB / DB carried out against water ingression.
5 Lugs properly pressed and terminated.(spot check few)
No loose connections at terminals & joints. (Spot check a few
6
wires).
7 Proper tagging on all cables with core marker is available.
JB TB's drawing placed in envelope in JB? (Optional but
8
preferable)
Cable's entering JB properly glanded with no opening for
9
dust.
10 Any spare cable entry points have blind plug.
11 No un insulated bus bars / joints.
12 No left over material & tools present inside.
13 Secondary winding of CTs , if used, is grounded at one end.
cables , entering or leaving metallic conduits are protected
14
from sharp edges
15 Fire catching material like paper, wood is not present inside.

Cables / Conduits / Fittings


1 Cable trays are not overloaded.
2 Fire proofing of the cable trays in the required area done.
3 Cables are away from steam-lines or other heat sources.
4 Distance kept between instrument signal & electrical cables
5 OT's on conduits have T facing downwards so water does not
fill up.
6 Sealing of conduits done
7 Armour is grounded at one terminal point
Cable bending radius is as per manufacturer's
8
recommendations.
Conduits for cables, if used, are chosen in a manner to
9
ensure recommended free space (40%) within the conduit.
10 Cable route markers are installed and protruded on surface.
11 Lugs are properly punched at core conductors.

Cables / Conduits / Fittings


1 Motor is as per area classification
2 Motor name plate matches with actual requirement.
Motor / Transformer is grounded at two different points on its
3
body
4 Check free rotation of motor before switching it ON.
5 Coupling guard is installed at motor coupling
Dummy test of Motor control circuit carried out before
6
switching it ON
All accessories of transformers are mounted and fitted on its
7
body
Functionality of Bucholz relay is established through dummy
8 test before switching ON the transformer.
9 Silica jell is filled in breather and its color is blue.

Special Instructions to Operator:


Any special procedure to take equipment in service, has
1
been put up?

Title

Project No. Date


Deficiencies to be corrected Before Responsibility Completed
Startup

Deficiencies correction Not Required


Before Startup Responsibility Completed

Unit /
Participation Name Designation Department Signature Date
Section
Team Leader

Member Production
Member HSE
Member Maintenance
Member TSD Project
Member TSD Inspection
Member TSD Process
Member E&I Electrical
Member E&I Instrument

ATTACHMENT 5: TEST AND STARTUP AUTHORIZATION FORM

Title
Project No. Date

Deficiencies to be corrected Before Responsibility Completed


Startup

Test Authorization: Date


Area Unit Manager

Startup of Equipment Authorized by Area Unit Manager Date

Project Closure:

All the recommendations listed in the PSSR have been completed.

Area Unit Manager Date

NOTE: The form (including all attachments and annexures) to be sent to the
Project Engineering in charge after the final signature by Operations Section
Head.

You might also like