0 28/12/2021 Issued For Review and Comments Ahmed Samir

Rev Date Description Issued By Checked By Approved

By
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Master Document Control

This document will be maintained live on the KPC Intranet. The Intranet based document
will be the controlled version and revision announcements will be distributed via e-mail to
relevant parties and published on the Intranet.

Copies or extracts of this document, which have been downloaded from the Intranet, are
uncontrolled copies and cannot be guaranteed to be the latest version.

The custodian of this manual is the Asset Integrity Managers and any suggested changes to
this procedure or queries about its applicability should be addressed to them.

The asset integrity managers are also responsible for coordinating periodic reviews of this
manual, which will take place every three years.

To Download the last version of Operational Readiness Manual, follow the below
link:

http://kpcweb.khalda-
eg.com/Operations/Asset_Integrity/SitePages/PSSR.aspx
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About the Guideline

This Manual illustrates KPC process and methodology for verifying that shut down processes are
in a safe condition for re-start, addresses startups for new project/equipment and also all types
of shut down conditions considering the length of time the process was in the shutdown.

The manual is intended to provide a guidance and direction on how to supply a final review on
the equipment to ensure process safety activities have been completed prior to adding any
hazardous chemicals to new or modified equipment.

The custodian of this manual is operational readiness administrator; also he is responsible for
coordinating periodic reviews of this guideline which will take place every three years.

The Asset Integrity Managers who are the system owner and any suggested changes to this
manual, system policy or system administrator shall be approved by them.

Guideline Approval

Mr. Mike Smith Eng. Ayman Ragab

Deputy Asset Integrity GM Asset Integrity Gen. Mgr.

Eng. Tamer Edris Mr. Ken Leong

Deputy Operations GM Operations Gen. Mgr.

Mr. Greg McDaniel Eng. Said Abdelmonim

General Manager & MD Chairman & MD
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1 Introduction
1.1 Preface
In recent years, there have been significant advances in process safety
management system, that aim to improve the safety and the integrity of
workplaces. Operational Readiness which known as Pre-Start Up Safety
Review (PSSR) system is one of the main elements of the process safety.
Khalda Petroleum Company (KPC) is continually seeking the improvement of
its rules and methods of identifying, managing the anticipated risks and
monitoring the directions where the industry is headed. Thus, KPC is
exploring certain changes to its rules and methods through the use of risk
based process safety.
The transition to a risk based framework through applying this manual and
other facility integrity management system (FIMS) manuals is expected to be
incremental while risk based and performance oriented approaches are being
developed and implemented.
To understand and apply this methodology, it is necessary that KPC
employees and management have a common understanding of the terms and
concepts involved and an awareness of how these concepts are to be
applied. This is the driving force for this manual.

1.2 Scope
This Manual illustrates KPC process and methodology for verifying that shut
down processes are in a safe condition to re-start, addresses startups for new
project/equipment and also all types of shut down conditions considering the
length of time the process was in the shutdown.

1.3 Purpose and Objectives

This manual is intended to provide a guidance and direction on how to start-
up equipment in a safely manner, and how to implement a successful
prestart-up safety review for KPC facilities.
This manual defines requirements for the following PSSR processes:
 Identification of hazards associated with start-up an equipment.
 Illustrates the different categories of prestart-up safety review.
 Guidance for selection of appropriate checklist to perform PSSR.
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 Responsibilities and approval requirements.

 Documentation, tracking and communication of PSSR results.
 Performance indicators and continuous improvement.
 Auditing of PSSR system.

1.4 List of definitions and abbreviations

Item Definition

Hazard Any source that has the potential to cause harm to people, property,
or the environment.

Risk Combination of the probability of an event and its consequence. In

some situations, risk is a deviation from the expected. When
probability and consequence are expressed numerically, risk is the
product.
It could also be defined as the effect of uncertainty on objectives (ISO
31000)

Hazard identification The process of identifying what hazards are associated with a given
operation, activity, or design.

Hazard and A hazard identification method that is formal, rigorous, and

Operability Review systematically used to identify deviations from the process design
(HAZOP) intent that may identify hazards or operability problems (or both).

Hazard evaluation The process of identifying what could go wrong, harm that could
result, and what controls are in place to develop a hypothetical
sequence of events (scenario) that might lead to an incident.

Risk management The systematic application of policies and practices to the tasks of
identifying, assessing, and controlling risk in order to protect human
life, the environment, physical assets, and company reputation in a
cost-effective manner. Risk management includes appropriate
stewardship and communication of results.

Risk assessment Overall process of risk identification, risk analysis and risk evaluation.

Abbreviations:
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Item Definition

PSSR Prestart-up safety review

HAZOP Hazards and Operability Review

MOC Management of change

RAMS Risk assessment and management system

FIMS Facility integrity management system

NORM Natural Occurring Radioactive Material

PSM Process safety management

PHA Process hazard analysis

PPE Personal Protective Equipment

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2 PSSR Process

2.1 Introduction
A Pre-Start-up Safety Review (PSSR) is intended to supply a final review of a
change to ensure process safety activities have been completed prior to adding
any hazardous chemicals to new or modified equipment.

A PSSR is required for new facilities/equipment or when a change has been

made to an existing facility or process that impacts process safety information
(this could include a change to the chemistry or the equipment).

Restarting a process in existing equipment can also pose a significant safety

risk, therefore a PSSR shall be performed if a process has been shut down for a
period of time (usually more than two weeks). The PSSR process also aligns
well with post-maintenance equipment checkout to make sure that equipment
properly checked after turnaround prior to restart.

1.2 PSSR types

PSSR is required for:

A- New facility/equipment:

In case of Installation of new facility or equipment that adds manufacturing

capacity to a production site, PSSR shall be mandatory to ensure safe start-ups.
Generally, these are changes that impact the infrastructure at a plant site,
where additional fire protection or environmental permitting is considered or
new, large capital equipment is installed.

It is more important to focus on the objectives of this activity rather than the
size of the capital budget involved. Projects that involve installing additional
fire protection, safety showers, breathing air stations, enhanced ventilation,
new heat transfer media, etc. shall be considered a facility change, and an
extended start-up checklist shall be used to assist with meeting the intent of
the pre-start-up safety review.
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Facility checklist in Appendix I shall be performed with this type. It is the most
extensive PSSR checklist and includes a check of safety systems (safety
showers, eyewash stations, help evacuate alarms, automation alarms, clear
paths for egress, etc.), as well as complete training and documentation.

B- When a change has been made to an existing facility or process

that impacts process safety information:

Any facility change that impacts the process safety information also requires a
PSSR. After the change executed and before the changed part put in service
the checklist take place to ensure the continuing operations integrity and safety
of personnel.

Checklist in Appendix II: PSSR CHECKLIST AFTER MOC shall be completed prior
to startup. It is a subset of the facility checklist usually focuses on the part of
the process that was changed, but still ensures that all of the following PSM
requirements are met:

 A PHR has been performed (if necessary), and recommendations have

been implemented or resolved.
 Construction and equipment is in accordance with design specifications.
 Safety, operating, and maintenance procedures are adequate and in
place.
 Training of each employee involved in the new or changed facility has
been completed.
An approval signature is required on the checklist in Appendix II: PSSR
CHECKLIST AFTER MOC before new or modified equipment can be started up.

C- Restarting a process in existing equipment that has been shut

down for a certain period (usually more than two weeks):
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Review of a Restart Checklist is recommended before restarting equipment after

maintenance, such as doing a replacement-in-kind or if a process is restarting
after a shutdown (usually more than two weeks).

For maintenance work, the PSSR team shall check out the equipment through
checklist in Appendix III to ensure the work is complete and the equipment is
ready to start-up before returning the equipment back to production to ensure
the process will restart safely.

If the shutdown of equipment has been longer than two weeks, a restart
checklist in Appendix III shall be done by PSSR team. If the shutdown has
been less than two weeks, the unit team could recommend a restart checklist
for appropriate reasons.

Checklist in Appendix III (PSSR CHECKLIST AFTER TURNAROUND/

SHUTDOWN) includes items such as checking for leaks on any equipment that
was opened, verifying valve lineup, checking for missing blinds or plugs on
drain and vent lines, replacing filter elements, cleaning strainers, restarting or
confirming operation of utilities, etc.

1.3 PSSR team members

The pre-start-up safety reviews shall be conducted by multidisciplinary teams
consisting of manufacturing (including operators), technical, design as-needed,
maintenance, appropriate safety representatives on an as-needed basis and the
Capital Projects originator/leader or the capital projects coordinator. When the
new facilities will be used by a resident contractor then a member of that
organization must take part in the PSSR.

For very minor changes, a smaller prestart-up safety review team may be used
and could consist of two team members. In this situation, the asset owner shall
designate the team members. Examples of minor changes include installation of
a new drain valve and instrument transmitter bracket modification.

Team composition is the key to maximizing the value and results of a PSSR. The
asset owner must take responsibility for assembling a multidisciplinary team
with knowledge and experience appropriate to the task. Team members should
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include personnel who were not directly involved on the applicable capital
project team.

The following points on team makeup are for guidance only:

 Even for the smallest PSSRs, such as those would be conducted prior to
starting up a single piece of equipment (e.g., a pump, heat exchanger, or
vessel), the team should have three or four representatives from different
backgrounds. This helps create a more searching and valuable review.
People who operate or maintain the facility (e.g., an operator and a
mechanic) should be included.

 Where the change involves introducing hazards (i.e., process, material, or

environmental) that are new to the site, the PSSR team should consider
including off-site personnel who have relevant knowledge and experience.
These could be manufacturing, maintenance, technical or appropriate
safety representatives.

 For significant capital projects and for larger projects, a formal PSM audit
may be recommended. In this case the asset owner must ensure that the
team has the skills and capability to carry this out. Consideration should
be given to having one or more safety or occupational health consultants
on the team.

 The leader of the PSSR team should foster an open atmosphere where
the project team members look on the review as an opportunity to
upgrade the process safety of the facility and do not become defensive of
the design or preparations for start-up.

1.4 PSSR team scope

Prior to the introduction of hazardous substances and associated energies to
a facility, the prestart-up safety review team shall confirm that:
 Construction and equipment are in accordance with design specifications
 All relevant elements of process safety management have been
appropriately addressed (i.e. PSM assessment).
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 For new facilities, a PHA has been performed and recommendations have
been resolved or implemented before start up and modified facilities
meet the requirements specified in MOC.
 Standard operating procedures and emergency procedures have been
developed to ensure safe operation of the new process.
 Basic safety, health, and environmental, also fire-protection items have
been checked during a physical inspection of the facility. These
inspections are usually guided via a previously pre-prepared “good
practice” checklist.
 Installation is in compliance with local regulatory requirements and site
and unit operating permit(s), including environmental air permits and
approvals.
 The facility is safe to start up. This may be contingent on completion of
certain recommendations.

1.5 Responsibilities of PSSR team members

1. System Owner (Asset Integrity Managers):

Responsible to ensure system manual is relevant and current. He shall

initiate manual review to upgrade the system as required and is the
management contact for any field management support or interpretation.
He shall also work with field management to encourage system
compliance and ensuring that the MOC process is followed by the field.

2. System Administrator:

Responsible for direct support to the implementation of the system in the

field. He is responsible for PSSR training programs and shall perform
annual PSSR key performance indicators review to ensure conformance to
the PSSR system described in this manual.

3. RAMS advisors:
Responsible for providing guidance through the PSSR process, Provide
helping in PSSR if invited to be a team member.
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4. Asset Owner (Department manager):

The Asset Owner shall designate the team members and shall authorize
the checklist after the team members have signed it and shall ensure that
all recommendations required prior to startup are completed and prior to
the introduction of hazardous materials into the facility.

5. PSSR Review Team Leader:

The Review Team Leader is responsible to;

 Assemble a multi-discipline team of subject matter experts

(member of the safety organization may also be included).
 Establish a review schedule for the team.
 Guide the team through the review using the checklist to ensure
that all relevant questions have been asked and answered.
 Consider developing additional equipment specific checklist that
may form the basis of a library.
 Document the answers to the checklist questions and note all
action items.
 Determine with the team if the action item can be corrected after
startup.
 Ensure that all action items are assigned to a specific person for
correction with due date and verifier.
 Document the date the recommendations are completed and initial
on the PSSR.
 Ensure all documents are filed with the MOC in the KPC database.
 Assist the team and asset owner with PSSR sign off.

6. PSSR Review Team members:

These personnel are selected based on their individual skills/knowledge

relative to the change being made. They shall use their individual skills
and knowledge to ensure that all relevant questions from the checklist
are correctly answered and that any additional concerns are brought
forward for discussion by the team. Members shall sign the checklist,
stating that the facility is safe to start up after completion of
recommendations required before startup.
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7. Field manager:

Responsible to approve the checklist of the new equipment/unit/facility

and ensure that all recommendations required prior to startup are
completed prior to the introduction of hazardous materials into the
facility. Facilitate performing the training in the field to boost the PSSR
system.

1.6 PSSR documentation record keeping

Asset owner shall Upload the checklist forms & documentations after
approval to designated folder in the share network of KPC data base,
Follow-up on recommendations generated during the safety review,
complete the assigned recommendations in a timely manner and
document the action taken in KPC database.
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3 Training and Competence

3.1 Introduction
All KPC employees and contractors in the company locations are responsible for
being adhere to process safety management system and PSSR is a vital
element in that system.

The Operational readiness program depends on the experience and

qualifications of the personnel involved. There are two categories of expertise
that classify personnel involved in the system (Basic and advanced).

Facilities business management, technical management, supervisory and staff

personnel as well as each operation, maintenance, and support team member
should be familiar with their potential participation in implementing the practice
of PSSR.

Some introduction to the concept and method of PSSR at a given facility is

often presented as part of a PSM new employee overview. But two major
categories of personnel may benefit from special consideration. The first
category (Basic one) is all the workforce staff and the second category
(advanced) is PSSR leaders and team members.

3.2 Training Programs

Training Level Expertise and Responsibility

Basic This level is the minimum level for all staff personnel to
be familiar with their potential participation in
implementing the practice of PSSR.
advanced This level is for individuals who participate in PSSR
team, utilize the PSSR checklists and understand the
system features.
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3.2.1 Basic training (the workforce staff)

Anyone involved in operating or maintaining a hazardous chemical process will

most likely have been trained in an overview of PSM, including pre-startup
safety review. This level of training may be enough for the general workforce.

Basic level risk assessment training provides operations and maintenance

personnel with appropriate understanding and skills to initiate and apply risk
control processes to work activities.

By the end of the course, participants are expected to:

 Have an increased awareness of potential hazards
 Understand the functioning of operational readiness system
 Be aware of their responsibility for enhancing the PSM culture in workplace.

3.2.2 PSSR leaders and team members

These trainees' roles indicate special attention to training design and

implementation. Assuming a familiarity of PSM and PSSR from an orientation
course or through day-to-day involvement in PSM activities, both the leaders
and the members of PSSR teams need to know how to navigate through the
PSSR program management system. Both the leader and the members could
benefit from training.

By the end of the course, participants should be:

 Able to participate as core PSSR team members.
 Define PSSR as it applies to this facility
 Discuss the benefits of performing PSSR.
 Access the facility's PSM element administrative procedure from the
facility document control system.
 Using the PSSR program PSM administrative procedure, walk through the
steps for a mock change in a tabletop exercise.
 Given a change or trigger event, identify potential members for an
associated PSSR team and explain why they were selected and what their
roles might be.
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 Given a change or trigger event, complete the PSSR documentation

(electronic or hardcopy) using the results of the tabletop exercise.

3.3 Personnel Competency

Personnel assigned to lead or participate in PSSR system shall have a level of
risk assessment and PSM training and experience commensurate with their
expected level of involvement in the process. Training is only one of the steps
necessary to achieve competency.

Pre-startup safety review team leaders shall benefit from additional training on
the following topics,
 Process Safety Management - Overview, current issues, and industry trends.

 How to Facilitate Meetings - Basic skills for preparing, leading and capturing
the results from meetings.

 Project Management - A basic course using facility project management

tools to schedule and complete activities to meet a goal.
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4 Performance indicators and continuous improvement.

If a process cannot be measured, it cannot be effectively managed. KPIs

provide the ability to manage the various business processes or activities
required to operate effectively.

KPIs can help boost each company’s risk related to PSSR understanding to
improve its operational readiness system and improve the whole PSM system.
KPIs can be used to assess system performance on a near-real-time basis and
at a more reasonable expenditure of effort.

Monitoring these key indicators can help KPC to detect the deviations in
implementing a PSSR system before these deviations can cause accidents.

Operational readiness system KPIs shall be:

- Important
- Applicable
- Time Balanced
- Simple
- Consistent
- Actionable
- Justified

Examples on some expected KPIs that could be used for PSSR in each company:

# KPI Description Concern Interval Responsible

1 Number of incidents A high number or increasing rate Annually PSSR Administrator

that occur during might indicate that PSSRs are not
startup being conducted in a careful
manner or that MOC was not
performed well.

2 Number of spurious A high number or increasing rate Annually PSSR Administrator

shutdowns after might indicate that PSSR
startup activities were not effective.

3 Number of A high number would indicate Annually PSSR Administrator

improperly that PSSRs were effective.
assembled pieces of
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# KPI Description Concern Interval Responsible

equipment found
during PSSRs

4 Number of A high number or percentage Annually PSSR Administrator

personnel trained might indicate that PSSR
prior to startup. activities were being performed
on schedule.

5 Duration of startup A high number might indicate Annually PSSR Administrator

that PSSRs were not performed
well.

6 Amount of off-spec A high number might indicate Annually PSSR Administrator

product or loss of that PSSR activities were not
raw material due to performed well or that MOC
startup problems activities did not address quality
hazards

7 Number of people A high number or percentage Annually PSSR Administrator

trained per year on would indicate an active PSSR
PSSRs. program.

8 Number of startups A high or increasing number Annually PSSR Administrator

for which PSSRs would indicate that the PSSR
were not performed program was being circumvented
and that remedial awareness
training might be in order.

9 Number of PSSRs A high number or percentage Annually PSSR Administrator

for which would indicate that PSSRs were
authorizations to not being finished off or
restart were not documented properly.
found.

10 Number of startups A high or increasing number Annually PSSR Administrator

deferred due to would indicate that the MOC
problems found process was not identifying all
during PSSRs. potential problems/hazards.

11 Number of field A high or increasing number Annually PSSR Administrator

revisions made would indicate poor PSSR
during startup to performance
deal with issues not
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# KPI Description Concern Interval Responsible

discovered during
the PSSR

12 Number of action A high percentage would indicate Annually PSSR Administrator

items completed a PSSR program that was vigilant
after startup in follow-up activities

13 Number of PSSRs A high or increasing number Annually PSSR Administrator

performed per would indicate an active program
month/year

14 Average amount of A high or increasing number Annually PSSR Administrator

calendar time taken might indicate the need to
from PSSR to improve efficiency or that the
completion of all MOC program was effective
action items

15 Person-hours A high or increasing number may Annually PSSR Administrator

expended on PSSRs indicate that efficiency
improvement or more resources
are needed
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5 Auditing

Operational readiness shall be included in PSM audit of all KPC facilities. The
auditing cycle maintains employee awareness of the overall PSM system. Audits
can be internal or external.

Internal audit typically means the facility audits itself or in a corporation with a
representative or appropriate positions from other plant, department within KPC
with no outside influence. This method brings outside experience and points of
view to a site and can be very helpful in sharing best practices as well as
communicating issues to other corporate facilities.

External third-party audits include an outside party to examine the system. This
can be a contractor, EGPC, or a customer. A third-party audit typically means
an outside consultant or organization comes in to look to system and compare
it with standards or regulations from yet another standpoint.

For internal audit Appendix IV: PSSR Auditing Questions shall be used in the
audit.
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Appendix I: PSSR CHECKLIST FOR NEW EQUIPMENT /UNIT /

FACILITY
Pre-startup Safety Review Checklist

Inspection Date:

Department/Area:

Project Number:

Title/Equipment:

HSE Group Date

Commissioning Group Date

Vendors / Process Engineering Group Date

Process Operation Group Date

Maintenance Group Date

QA Group Date
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Checklist Item Details (reference category / Responsibility Complete

No. item no.)
Sign & Date

Category A Action Items - Items to be completed BEFORE authorization and start-up

1.

2.

3.

4.

5.

Category B Action Items - Items to be completed AFTER start-up

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.
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Area Authority Feedback:

All “before start-up” items are completed / uncompleted and can / cannot start the
equipment / unit / facility.

Comments:

Authorized: Facility/Equipment Owner Signature: Date

Approval for Start-up:

It is accepted to start-up the new equipment / unit / facility, as the pending items will not
have effect on the safe operation for the new equipment / unit / facility, The area authority
can go ahead with start-up procedure.

Authorized: Field General Manager Signature: Date

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PSSR CATEGORY/ITEM TO ASSESS (Yes / Item Remarks

ITEM NO. No / Category
NA) (A/B)

1.1 GENERAL SAFETY

1.1.1 Have ALL appropriate personnel (Operations,

Maintenance, Technical, and Supervision)
received adequate and appropriate training on
the equipment and operating procedures?

1.1.2 Has adequate and appropriate 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?

1.1.3 Have measures been taken to adequately

guard all dangerous parts of this equipment?

1.1.4 Has sufficient provision been made for the

electrical and/or mechanical isolation of the
equipment?

1.1.5 Are points of isolation clearly marked/labeled

and readily accessible?

1.1.6 Has proper guarding, handrails/barriers, been

provided to prevent falls?

1.1.7 Have all hot/cold surfaces been adequately

guarded to prevent burns? Are all cold
surfaces adequately insulated to prevent
condensation drips (slip hazards)?

1.1.8 Are Safety Showers and Eye Wash facilities

provided and adequately marked?
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Are the Safety Showers and Eye Wash

facilities routinely inspected?

Do the Safety Showers and Eye Wash facilities

locations comply with Corporate guidelines?

Are the Safety Showers and Eye Wash

facilities readily visible and accessible?

1.1.9 Has sufficient lighting been provided so that

operation, servicing, maintenance, and repair
of the facilities can be carried out safely?

1.1.10 Have 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?

1.1.11 Are all of the applicable Work Permit,

Procedures (Confined Space Entry, Lock
Out/Tag Out, Hot Work, High Work, etc.) in
place?

Have the Operating, Maintenance, and

Supervisory personnel been properly trained
on the Work Permit Procedures?

1.1.12 Have the fire protection systems been

inspected by the insurance company? Has
acceptance testing been completed and
documented?

Is there an agreed on test and inspection

program for the fire protection systems
(including alarm systems)?

1.1.13 Are other Safety aids such as portable LEL

meters, Oxygen meters, barricades etc.
available at identified locations?
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1.1.14 Are walkways and other working surfaces in

the area level and free from potential tripping
and fall hazards?

1.1.15 For lifting devices such as cranes and hoists,

have load tests been completed and marked
with load ratings?

1.1.16 Have proper handrails, barriers or similar

perimeter protection been provided to prevent
falls from elevated surfaces?

1.1.17 Radioactive sources stored properly as per

statutory requirements.

1.1.18 Platforms ladders checked & found clean,

accessible & safe. No openings left in the
platforms.

1.1.19 Housekeeping and congestion can have an

impact on safety and operability. Equipment
accessibility, disposal of garbage and scrap,
marking on roads, pavement, storage area for
tools, signage etc. have been checked?

1.2 MACHINERY/EQUIPMENT SAFETY

1.2.1 Has the machinery/equipment been installed

so that it will be stable and secure during
operation?

1.2.2 Has all access to dangerous moving parts, or

danger zones created by the equipment, been
prevented by the provision of the correct
guards, interlocks (both safety & non-safety)
and/or barriers?

1.2.3 Have 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?
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1.2.4 Has safe access been provided to the

equipment that requires operator and
calibration and maintenance personnel access
for normal operations, adjustments, service,
calibration, maintenance, or repair?

Has slip, trip, trap, crush, entanglement, fall,

bump, and cut hazards been minimized?

1.2.5 Is the equipment provided with the properly

identified START/STOP and EMERGENCY
controls that are positioned for safe operation
without hesitation, or loss of time, and
without ambiguity?

1.2.6 Is the equipment provided with a clearly

identified means to securely isolate it from
ALL energy sources? (LOTO)

1.2.7 Mechanical equipment have been checked for

proper alignment, lubrication, back flow
prevention and rotation; functional checkouts
have been performed on equipment and
controls?

1.2.8 All equipment has been filled with proper

fluids to the appropriate level and charged as
necessary?

1.3 ERGONOMICS

1.3.1 Have the 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?

1.3.2 Has the need to lift, carry, push or pull heavy

loads, or parts, been eliminated to the extent
possible?
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1.3.3 Are all display screens, dials and

START/STOP/ EMERGENCY buttons
positioned so that they are readily visible and
accessible by the operating personnel?

1.3.4 Have Visual Display Screens been positioned

so that interference from glare is reduced to
the minimum?

1.3.5 Have workstations been designed 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.)

1.3.6 Are there any lifts that exceed the general

guidance limits that should be added to the
site priority list? (55 lbs./25kg for good lifting
conditions, 30 lbs./14 kg for less optimal lifts,
and 80 lbs./36 kg for a two-person lift)

1.4 OCCUPATIONAL HEALTH AND HYGIENE

1.4.1 Have 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
engineering controls utilized to minimize the
risks?

1.4.2 Has adequate RPE (Respiratory Protective

Equipment) been specified in the Operating
Procedures?
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1.4.3 Have the Operating Procedures been

reviewed to take into account any additional
“health hazards” which may arise from
operation or maintenance of this equipment?

1.4.4 Has adequate LEV (Local Exhaust Ventilation)

been installed, tested, balanced, and entered
on an Inspection Schedule?

1.4.5 Have adequate inspection and cleaning ports

been provided in all ductwork intended for
exposure control? If filters are part of the LEV
design, have they been installed and included
on a periodic cleaning or replacement
schedule?

1.4.6 Are relief facilities directed to a safe place

away from the workplace?

1.4.7 Has all insulation been identified?

1.4.8 Has a noise survey been considered and if

so, has area noise monitoring been
scheduled to identify potential boundaries of
hearing protection and posting?

1.4.9 Has all pipe work, tanks, and equipment

containing hazardous materials been
adequately labeled?

2.0 PROCESS SAFETY

2.1 PROCESS TECHNOLOGY

2.1.1 Are up-to-date Material Safety Data Sheets

available?

2.1.2 Have the hazardous effects of inadvertent

mixing of different materials been considered
(that is, has a chemical interaction matrix
been prepared/updated)?
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2.1.3 Has the process design basis been

documented or updated? Has the control
philosophy and sequence of operations been
documented?

2.1.4 Has the equipment design basis (for example

PFD/P&IDs) been documented / updated?

2.1.5 Have the recommendations from safety

reviews, Process Hazards Analysis (PHA),
Hazards and Operability Reviews (HAZOP),
or others, been implemented?

Record any incomplete items.

2.1.6 Are 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?

2.1.7 -Have the pressure relief device calculations

been provided?

-Does the sizing of pressure relief devices

agreed with the calculated sizes?

-Do the calculations take into the

downstream piping?

2.1.8 Do the relief devices vent to safe locations?

Is containment provided for liquids and solids

released from pressure relief devices?

2.1.9 Are 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
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inhibit the operation of the pressure relief

devices.

2.1.10 Are all pressure relief devices included in the

Preventive Maintenance Program?

Are the inspection and testing of relief devices

in accordance with local regulations?

2.1.11 Has the process technology package been

updated including any new or modified
hazards of materials or energies?

2.1.12 Has the material and energy balance been

updated as applicable?

2.1.13 Have all vendor instruction manuals been

obtained and identified were applicable?

2.1.14 Has the site and unit electrical classification

drawing been updated?

2.2 MANAGEMENT OF CHANGE – TECHNOLOGY/ MANAGEMENT OF SUBTLE CHANGE

2.2.1 Has a management of change –

technology/subtle change document (for
example, Change of Design - COD) been
approved?

2.2.2 Has a test authorization been approved?

2.2.3 Are all action items, arising from the COD,

that were deemed necessary for start-up,
complete?

2.2.4 Have all changes made during construction

been recorded and authorized?

Have hazards evaluations (PHAs, HAZOP)

been done on all the changes made during
construction?

2.3 QUALITY ASSURANCE

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2.3.1 Have checks and inspections been made to

ensure that critical equipment is installed
properly and is consistent with design
specifications and vendor’s recommendations
(for example, alarm and interlock (safety &
non-safety) tests; equipment alignment and
service to process inter-connections)?

2.3.2 Have quality assurance inspection reports,

covering fabrication, assembly, and
installation, been completed in accordance
with the project’s quality assurance plan and
reports filed with the equipment and design
basis documentation?

2.3.3 List specific items field checked as part of this

Pre-Start-up Safety Review to ensure that:

-Does construction meet the design

specifications?

-Does construction match the drawings?

2.3.4 Have the following documented been

provided and approved:

Instrument indexes and instrument loop

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 codes?

Welder certification? Non-destructive test

(NDT) certifications?

Electrical certification for classified areas?

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2.3.5 Were all aspects of the project QA plan

completed as planned?

2.3.6 Have quality assurance inspection reports,

covering fabrication, assembly and
installation, been completed in accordance
with the project’s quality assurance plan and
reports filed with the equipment and design
basis documentation?

2.4 OPERATING PROCEDURES AND SAFE WORK PRACTICES

2.4.1 Standard operating procedures been

prepared/updated and approved?

2.4.2 Do the operating procedures cover:

Initial start-up?

Normal start-up?

Normal operations?

Normal shutdowns?

Emergency operations including emergency

shutdowns?

Start-up after emergency shutdowns? Start-

up following turnarounds / prolonged
shutdowns?

2.4.3 Non-routine procedure such as equipment

clean-outs and preparation of equipment for
maintenance?

Auxiliary equipment operations including as

examples; LEV and Ventilation Systems,
Heat/Cool Skids,

Water (Soft, RO, WFI, Tower, etc.)

Systems, Instrument and Process Air Systems,

Waste Treatment Systems,
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Cooling (Glycol Refrigeration) Systems, Steam

Generation, and others?

Safety and operational issues?

Change control procedures?

2.4.4 Have lock-out tag-out procedures or checklists

been developed for equipment specific
isolation tasks?

2.4.5 Job Risk analysis carried out for critical

procedures and precautions incorporated in
procedures?

2.4.6 Emergency shutdown push buttons are clearly

marked up and protected against inadvertent
operation?

2.5 TRAINING AND PERFORMANCE

2.5.1 Has specific process (or job task) training

been given to personnel?

2.5.2. Have training records been updated?

2.5.3 Has initial training and qualification testing

been completed for all operating personnel on
new or modified equipment and facilities
based on operating procedures?

2.5.4 Has the operating technician refresher

training and development schedule or matrix
been updated to reflect new training and skill
demonstration requirements to match any
changes in equipment or facilities?

2.6 INTERLOCKS AND ALARMS (ALARMS AND SAFETY INSTRUMENTED SYSTEMS )

2.6.1 Has a functional safety assessment for all new

safety instrumented functions (SIF) been
completed and documented?

2.6.2 Have all instrumentation installed to

engineering design specifications?
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2.6.3 Did the team check that the alarm/interlock

action proved, under all conceivable failure
conditions, to be fail-safe?

2.6.4 All bypasses and jumpers on control or safety

circuits have been removed?

The fire and gas detection systems have been

inspected and tested and are in auto mode?

2.6.6 Has an interlock/critical alarm Standard

Operating Procedure for testing been written
and implemented prior to this PSSR?

2.6.8 Do you have an appropriate procedure to

ensure that your software is protected? (e.g.
routinely archived, key/password protected
etc.).

2.6.9 Has the software been properly documented

and filed? (e.g. logic drawings, schematics,
sequence/batch descriptions)?

2.6.10 Has all software has been validated and

tested?

2.6.11 Have you ensured that the equipment does

not restart either on the resetting of a
protective device such as an interlock or the
reestablishment of power after an outage?

2.6.12 DCS data base including graphics are checked

and are as per approved Engineering
documents?

2.6.13 DCS reliability is proven?

2.6.14 All flow meters including those at B/L

calibrated, meter constants approved by TS

2.6.15 Initial tuning constants set as per licensors

recommendation?

2.6.18 Redundancy of Control system checked

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2.6.19 Reliability of power supply to DCS/ other panel

checked & proper earthing ensured.

2.6.20 All instruments loops checked. Records

available

2.6.21 All control valves stroked – records available,

Air failure actions recorded & ok.

2.6.22 Field process control valves set points ok.

2.6.24 Leak Test of all impulse tubing done and is

satisfactory

2.6.25 Arrow marking done near all orifice plates and

orifice diameters are checked again

2.6.26 Has all appropriate process technology been

updated (for example, interlock lists, P&IDs,
logic drawings, etc.)?

2.6.27 Does your Control System documentation

adequately specify:

2.6.28 All major components and their model and

serial numbers?

2.6.29 All communication cables layout and

configuration?

2.6.30 Any configurable or custom settings and set-

up?

2.6.31 Has consideration been given to suitable fire

detection and prevention systems for the
equipment?

3.0 CAER (COMMUNITY AWARNESS EMERGENCY RESPONSE)

3.1 Have all necessary precautions been taken to

ensure that the equipment is not a source of
ignition to any flammable materials,
irrespective of their source?
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3.2 Are fire protection facilities adequate for

example, fire extinguishers, fire walls,
sprinkler systems, Alarm Boxes, etc.)?

3.3 Are Emergency Escape Routes, including

ladders, adequate and properly signposted?

3.4 Is emergency lighting adequate?

3.5 Is sufficient Respiratory Protective

Equipment, such as Escape Sets or Self-
Contained Breathing Apparatus (SCBA)
available?

3.6 Have Emergency Procedures been prepared

and relevant personnel trained?

4.0 ELECTRICAL SAFETY

4.1 Has an Electrical Safety Checklist (Acceptance

of Electrical Installations) been completed by
a competent personnel?

4.2 Has the equipment been properly installed

and constructed to Corporate guidelines and
local legislation, and does it meet any special
installation requirements noted on the
manufacturer’s certificate?

4.3 Has equipment been designed and purchased

for the conditions under which it will operate
(for example, hazardous areas)?

4.4 Are all live parts adequately enclosed to

prevent access?

4.5 Does grounding and bonding comply with

corporate and local standards/legislation?

4.6 Have fuses or circuit breakers been provided

which will automatically disconnect the
supply?
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4.7 Are single line drawings and PPE requirements

available in Motor Control Centers (MCC),
Electrical Control Rooms (ECR)/Sub-stations,
as appropriate?

4.8 Have all relevant documentation and drawings

(for example, P&IDs, SLDs, Schematics,
equipment arrangement, I/O, logic, electrical
classification and Panel Schedule drawings)
been updated to reflect the current
installation?

4.10 Have operations or areas been electrically

classified?

4.11 Is accurate documentation needed to allow

planning of energy isolation and lockout/tag-
out as required by local standards?

4.12 Has the arc flash hazard assessment, if

applicable, been completed and equipment
arc flash hazard labeling installed?

4.13 Availability of UPS/ battery backup checked,

trials taken

4.14 No load trials of all motors taken

4.15 Emergency power availability for illumination

4.16 Auto changeover of feeders checked

4.17 Electrical power load shedding schemes

finalized & tried where possible.

4.18 Relay settings validated & tested.

4.19 Lighting in the plant including street lighting

is adequate to enable all activities safely.
Illumination survey done.

4.20 Transformer location is accepted?

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5.0 FIELD VERIFICATION

5.1 Is the normal lighting adequate for normal

and maintenance operations?

5.2 Is emergency lighting sufficient?

5.3 Are all hot and cold surfaces, which may

cause burns, in the proximity of personnel
insulated?

5.4 Are all instruments, equipment and piping

adequately labeled?

5.5 Is there any rusted and/or damaged

equipment?

5.6 Are swing gates or chains installed at the top

of ladders and/or on access platforms?

5.7 Are there any gaps between platforms and

equipment that could create a foot hazard?

5.8 Is equipment and platform access adequate?

5.9 Do safety showers/eye wash stations create

a hazard to personnel (slips), potential for
contamination of product (entry to
equipment) or ingress to electrical
equipment?

5.10 Are safety showers and eye wash stations

adequately marked and readily visible?
Is the access to the safety showers and eye
wash stations uninhibited?

5.11 Are all pipelines labeled?

5.12 Are all electrical switches, disconnects, MCCs,

control panels, cables, etc., labeled?
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5.13 Is all the equipment clearly labeled? Where

required are the materials and hazards
included on the labeling?

5.14 Are wall penetrations adequately sealed?

5.15 Are electrical conduits sealed in accordance

with code requirements?

5.16 Are evacuation routes clearly marked?

5.17 Are fire extinguishers installed properly?

5.18 Has the required signage been posted?

5.19 Are emergency stops provided where there is

a potential for entrapment or exposure?

5.20 Has all scaffolding and construction

equipment been removed?
Is housekeeping acceptable?

5.21 Is all required equipment guarding installed

5.22 Does all the applicable equipment have the

required CE marking displayed?
Does all the applicable equipment have the
required UL listing/labeling?

5.23 Piping is routed according to the P&ID and

isometric & Valves are installed and
orientated correctly.

5.24 Inspect valves, flanges specs to confirm

proper material, pressure rating and
compatibility.

5.25 Flange installations have been inspected for

proper bolting, gaskets, isolation kits, and
restriction orifices.
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5.26 All filters, screens, and strainers (temporary

or permanent) are properly located and
installed.

5.27 All permanent blinds are in place; all

temporary blinds have been removed. The
blind list has been updated and approved.

5.28 Supports required meet design structural

engineering standards.

6.0 HAZARD COMMUNICATION

6.1 Have all Material Safety Data Sheets been

obtained, created, or modified where
applicable for raw materials, intermediates,
finished products and wastes?

6.2 Has fixed equipment been properly labeled to

identify hazards based on site policies (hazard
warning labels on storage tanks, vessels,
piping, etc.)?

7.0 EMERGENCY RESPONSE PLANS

7.1 Have emergency response pre-plans been

updated or created based on any changes to
equipment, facilities or hazards?

7.2 Are there any off-site ER related

communications needed for changes (local ER
or community organizations)?

7.4 Are all assembly or similar points of

evacuation and assembly in case of an
emergency properly identified and
communicated?

7.5 Are there any updates required within the site

Emergency Operations Center (EOC) related
to these changes?

7.6 Wind socks installed & are visible from all

areas.
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8.0 PROCESS VENTS

8.1 Flammable liquid breather vents provided with

flame arrestors or conservation vents

8.2 Pressure gauge or other indicator provided

between rupture disc and relief valve where a
disc is installed below a relief valve

8.3 Venting to a safe location confirmed

8.4 Excessive length of flame arrestors

8.5 Provisions such as drain holes to prevent

accumulation of rainwater in discharge piping

8.6 If isolation or intervening valves are present,

an administrative procedure is in place to lock
in open position with chains/car seals or
equivalent

8.7 Discharge piping adequately supported to

withstand reactive forces of pressure venting

8.8 is safety relief valves test certificates available

and correct safety valve is installed as per
datasheet?

8.9 is safety relief valve gagged or isolated?

9.0 Fire Protection

9.1 Does this project change the relative rating of

the site fire safety management plan (FSM) in
terms of risks and required
resources/expertise?

9.2 Is a maintenance plan and personnel in place

for all new fire safety equipment?

9.3 Are country or local jurisdictional permits,

documentation for government agencies
updated where applicable?
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9.4 Are fire separations identified and maintained

properly to prevent fire spread including
separations between operations and storage
areas?

9.5 Are all openings in fire separations properly

protected (fire doors, dampers, stoppings)

9.6 Have all new fire doors, fire dampers, etc.,

been added to the appropriate inspection and
maintenance programs?

9.7 Have the new fire doors, fire dampers, etc.

passed an acceptance test?

9.8 Are all other requirements for life safety still

met (travel distance, access to multiple means
of egress, protection from hazards)?

9.9 Is garments made from other flame resistant

fibers worn by personnel who work with
flammable liquids/gases or combustible dusts
presenting a flash fire hazard?

9.12 Are all necessary Emergency warning signs,

lights or other devices installed where
necessary?

9.13 Have all new Emergency warning signs, lights

or other devices been added to the
appropriate inspection and maintenance
program?

9.14 Have NFPA 101 (Life Safety Code) and Local

Requirements been addressed?

9.15 Installation of Fire hydrants, Fire monitors,

Foam pourers, Sprinklers as per drawings
verified

9.16 All Fire water piping checked and is as per

drawings
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9.17 Location of sensors as per drawing verified

:LEL sensors, Smoke detectors, Toxic gas
detectors, IR/ UV detectors, MCPs

9.18 Calibration/ Actuation of sensors checked,

settings as per recommendations & records
available: LEL detectors, Smoke detectors,
Toxic gas detectors

9.19 Passive fire protection system including

fireproofing completed as per drawings.

9.20 Are all fixed fire suppression systems installed

according to design and supplier instructions

9.21 Does the site fire water supply have sufficient

capacity to supply the design demand for the
specified duration (one to four hours –
depending on the severity of the hazard)?

9.22 Can the fire pumps deliver 100% of the

maximum fire water demand at the required
pressure for the largest credible fire expected
to occur on the site?

9.23 Have new sprinkler systems been tested to

insure they meet the Acceptance
Requirements of the applicable NFPA
standard?

9.24 Are all the facilities that handle flammable

liquids fully protected with water spray, foam,
or other automatic suppression system that
complies with a nationally recognized code or
standard?

9.25 Are additional fire hydrants/monitors installed

and not obstructed in operation?

9.26 Are dry/wet riser systems installed, tested

and not obstructed in operation?
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9.27 Is adequate drainage or curbing containment

provided to control contaminated firewater
runoff?

9.28 Are all new fire suppression systems added to

the appropriate inspection, test and
maintenance program?

9.29 Is all portable fire extinguishing equipment

located in proper locations along normal
paths of travel, including exits from areas,
and will this equipment be properly
maintained per NFPA 10

9.30 Are fire & smoke detectors installed and is

there an inspection and test program?

9.31 Is the deluge valves operation tested?

9.32 Are "Emergency Escape Routes" including

ladders properly marked and there is no
obstacle in their path?

9.33 Locations of Fire extinguishers, PA phones,

Safety showers clearly identified as per site
standard

9.34 Are fire protection facilities adequate, e.g. Fire

extinguishers, fire walls, sprinkler systems,
Alarm Boxes, etc., and have they been
included on Inspection Schedule?

9.35 Have all necessary precautions been taken to

ensure that the equipment is not a source of
ignition to any flammable materials,
irrespective of their source?

9.36 Are all necessary Emergency warning signs,

lights or other devices installed where
necessary?(aviation lights, perimeter lamps
etc.)

10.0 Security and Access Control

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10.1 Has the Site Security Leader reviewed the

changes to evaluate the potential need for
security enhancements? (e.g., access control,
new procedures, equipment upgrades)

10.2 Has the Site Security leader evaluated

whether or not these changes impact
additional security regulations?

10.3 Material gate pass (returnable &

nonreturnable procedures) system in place.

10.4 Red, Blue, Green roads identified & suitable

barricades provided & vehicle entry restricted.

10.5 Operational Area fenced off, Gates closed,

keys available with Shift Engineer's office

10.6 Entry of unwanted contractor’s staff

restricted

10.7 Procedure for tracking movements of tankers

within site is in place.

10.8 Security surveillance cameras installed & are

functional.

10.9 Visitor Control procedure in place

11.0 OTHER

11.1

11.2
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Appendix II: PSSR CHECKLIST AFTER MOC

Pre-startup Safety Review Checklist

Inspection Date:

Department/Area:

Title/Equipment:

MOC Reg. No.:

MOC Title:

HSE Group Signatures:

Process Operation Group Signatures:

Maintenance Group Signatures:

(Mechanical/Electrical/Instrumentation)

Inspection/ Corrosion Group Signatures:

Others Signatures:
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Checklist Item Details (reference category / Responsibility Complete

No. item no.)
Sign & Date

Category A Action Items - Items to be completed BEFORE authorization and start-up

1.

2.

Category B Action Items - Items to be completed AFTER start-up

1.

2.

3.

4.

5.

6.

7.

8.

Area Authority Approval for Start-up:

It is accepted to start-up the equipment, as the pending items will not have effect on
operating safely.

Authorized: Facility/Equipment Owner Signature: Date

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PSSR ITEM CATEGORY/ITEM TO ASSESS (Yes / Item Remarks

NO. No / Category
NA) (A/B)

1. ADMINISTRATION

1.1 Based on the current design, is the proposed

change consistent with the original Process
Hazard Analysis (PHA) assessment?

1.2 Does the design comply with corporate

standards?

1.3 Has the impact of the change on existing

buildings been considered? (That is, the design
and location of new or modified equipment near
occupied buildings, occupying a previously
unoccupied building, and others.)

1.4 Has any impact, beyond unit boundaries,

associated with this change been properly dealt
with and/or communicated?

1.5 Have exposures to existing buildings (including

pipe racks and cable trays) been considered
when siting new vessels, utilities,
temporary/permanent buildings or sheds, and
others?

1.6 Have noncombustible materials or construction

been used?

2. MATERIAL SAFETY/REGULATORY STATUS

2.1 Have the following change scenarios been

considered for possible Toxic Substance Control
Act (TSCA) applicability?

a. Previously non-isolated intermediates being

temporarily isolated
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and/or held even for a short time, in non-hard-

piped process equipment or in storage vessels
(for example, drums).

b. Previously non-isolated intermediates being

held for an extensive period (for example, 24
hours or longer) in hard piped process
equipment.

c. Material previously burned or disposed of as

a waste is reprocessed or sold.

d. Different reactants or catalysts or different

feed ratios are being used, thus producing
different reaction products for TSCA purposes.

e. Change in the components or reactants in a

polymer from < 2 % to > 2 % of the dry weight
of the polymer produced.

f. The TSCA Inventory status of different

catalysts or reactants is unknown. If any of the
above change scenarios are about to happen,
contact the plant TSCA Coordinator immediately
for an in depth station of TSCA issues. Provide
documentation of any concerns and their
resolution.

2.2 Have Material Safety Data Sheets (MSDS) or

Preliminary Product Safety Data Sheets (PPSDS)
been obtained for all chemicals to be handled,
including isolated intermediates? (Consider
changes in minor components of products and
byproducts)

2.3 Has the potential for a hazardous chemical

reaction in sumps and sewers been considered?

2.4 Have all other potential product regulatory

issues been addressed, for example,
Department of Transportation (DOT), Federal
Insecticide, Fungicide, and Rodenticide Act
(FIFRA), Bureau of Alcohol, Tobacco, and
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Firearms (BATF), Food and Drug Administration

(FDA) and ISO 9001?

3. PRESSURE/VACUUM RELIEF

3.1 Have new or modified safety relief device(s) or

vent system(s) been designed in accordance
with Plant Engineering and Site requirements?

3.2 Has potential for external pressure (vacuum)

from sudden cooling, condensing, pump-out,
during clean-up or preparation of equipment for
maintenance, or potentially submerged overflow
line been addressed?

3.3 Have only full-port valves been specified for use

at the inlet and outlet of pressure/vacuum relief
devices?

3.4 Have any changes to safety relief device inlet or

outlet piping been properly reviewed?

3.5 Will adequate facilities (alarms, detectors,

redundancy, and others.) be provided to
minimize the risk of a relief device actuating due
to equipment, instrumentation, or utility failure?

3.6 Have the discharges of safety relief devices

been located so as to avoid potential personnel
injury and damage to associated equipment?

3.7 Has the design included installation of the safety

relief valve vertically?

4. TEMPERATURE/REACTION

4.1 Has potential for formation of unwanted by-

products been adequately addressed?

4.2 Has potential for loss of flow or reverse flow

been adequately addressed?
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4.3 Have adequate provisions been made so that

normally dilute but reactive materials CANNOT
be concentrated or accumulated in unexpected
areas (stagnant pipe/valves; utility systems;
feed or reaction vessels, sewers, and others)?

4.4 Is adequate freeze protection provided?

5. VALVES AND PIPING

5.1 Have the proper valve and piping specifications

been used?

5.2 Have cross-tied lines (pump headers, utility

lines, between high/low pressures, and others.)
been reviewed to minimize contamination
potential and eliminate mixing of reactive
chemicals?

5.3 Have test methods and documentation

requirements been specified to ensure the
integrity of new and revised piping systems?

5.4 Will sample points be properly configured for

safe sampling of hazardous chemicals?

5.5 Have all open ended valves and hand-operated

ball valves been designed in accordance with
environmental requirements (that is, NESHAPS
covered materials such as benzene and
formaldehyde) or plant standards?

5.6 Have hot-taps been reviewed and eliminated

where possible?

5.7 Will necessary excess flow and back-flow

prevention measures be provided?

5.8 Has line expansion and vibration during startup,

shutdown, cleaning, normal operation, and
others, been considered, and, if appropriate,
analyzed in detail?
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5.9 Has the potential risk and consequences of

hydraulic hammering been considered?

5.10 Have appropriate materials of construction been

considered for compatibility, corrosion
resistance and GMP requirements? (Consider 0-
rings, gaskets, diaphragms, and others.)

5.11 Have the temporary start-up strainers been

identified to ensure removal for normal
operation?

5.12 Has the design included the proper encasing of

underground piping at stress points (for
example, roadways, railroads, and others.)?

6. ROTATING AND MECHANICAL EQUIPMENT

6.1 Have special precautions for safe operation of

equipment been considered? (Reverse flow,
minimum flow, maximum head, sudden flow
increase during startup, total recycle, vapor
locking, volute drainage, Emergency Shutdown
Device(s) (ESD), and others.)

6.2 Do new and revised pumps and/or pump seals

meet and GMP requirements and corporate
standards?

6.3 Have lubricants and buffer fluids been properly

selected to meet any GMP requirements (that is,
food grade) such that leakage into the process
will not result in undesired chemical reactions or
product contamination?

6.4 Will moving parts on machinery be properly

guarded?

6.5 Will pumps be located in accordance with

corporate standards?
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6.6 Are the emergency shutdown systems (over

speed, ground fault, high temperature,
vibration, and others.) adequate?

6.7 Have appropriate materials of construction been

considered for compatibility, corrosion
resistance and GMP requirements? (Consider 0-
rings, gaskets, diaphragms, and others.)

6.8 Will adequate pressure relief be provided for

new or modified pump systems?

7. INSTRUMENTATION

7.1 Has the potential for instrument failure been

adequately addressed?

7.2 Have all new shutdown devices been designed

to permit testing.

7.3 Have potential consequences of instrument or

computer failure (redundancy, backup power
supply, or others) been considered?

7.4 Has control valve fail-safe position on loss of

electric power or air/nitrogen been properly
specified to minimize the impact of failure?

7.5 Have provisions been made to safeguard

against risks associated with control valves
going full open or closed (mechanical stops, limit
switches, and others.)?

7.6 If the change affects a shutdown or ESD system,

have issues been addressed?

7.7 Will the alarms associated with critical

instruments be clearly displayed in the control
room?

7.8 Have any special concerns with regard to

response time or sequencing been adequately
addressed? (Consider over speed trips,
hydraulic hammer, surge control, and others.)
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7.9 Have process changes (capacity change,

density, viscosity, vapor pressure, and others)
been considered in the design of new and
existing instrumentation?

7.10 Has ESD control logic been reviewed?

7.11 Will temperature elements be mounted in

thermo-wells?

7.12 Have appropriate materials of construction been

considered for compatibility, corrosion
resistance and any GMP requirements?
(Consider 0-rings, gaskets, diaphragms, and
others.)

7.13 Has adequate local instrumentation been

addressed for safety and trouble-shooting
purposes?

7.14 Is the location of sensing elements proper to

ensure that they are actually measuring what
you want measured?

8. ELECTRICAL SYSTEMS

8.1 1 Have instrumentation and electrical

equipment enclosures been specified to meet
the electrical classification of the area?

8.2 Have wire gauges, starters and overloads been

properly sized in accordance with the National
Electric Code (NEC)?

8.3 Has the design considered the requirements of

electrical hot work and cranes near power lines
such that outage requirements and variances
will be minimized?

8.4 Has the design included adequate room for

ventilation of transformers, motors, and other
similar equipment?
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9. FIRE PROTECTION

9.1 Has the potential for static electricity buildup

been adequately addressed?

9.2 Has proper grounding of all electrical and

process equipment (including piping and
shipping containers) been specified?

9.3 Will fire containment be adequate where

hazardous or reactive chemicals are present
which can result in high energy release when
mixed, contaminated, heated or otherwise
mishandled?

9.4 Has spontaneous heating of leakage into

insulation been adequately considered?

9.5 Are provisions made for safe handling of

flammable or potentially explosive materials?
Consider materials of construction, cleanup and
preparation of equipment for maintenance.

9.6 Are all fire water spray-system modifications

being designed (including flow calculations) and
installed by qualified personnel or contractor?

9.7 Have modifications or additions to fire

protection systems been reviewed or accepted
by the safety department or property insurance
carrier?

9.8 Will vents potentially containing flammables be

provided with adequate safety equipment
(flame arrestors or inert gas purge system)?

9.9 Will an adequate detection (vapor or explosive

gas detectors) and response system be provided
where a vapor cloud is likely?

9.10 Have the risks associated with any ignition

source or explosive gas mixture been
adequately dealt with?
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9.11 Has adequate fire safety equipment been

specified and located where needed?

9.12 Has deluge water overflow from containment

systems been determined and reviewed
properly?

9.13 Is diking, curbing, or drainage adequate to

contain spills and contaminated rainwater?
[Resource Conservation and Recovery Act
(RCRA)]

10. PERSONNEL HEALTH & INDUSTRIAL

HYGIENE

10.1 Does the design adequately consider medical,

industrial hygiene, ergonomic and GMP factors
(heat stress, biological stress, high noise level,
poor lighting, adequate ventilation, potential of
oxygen deficient atmosphere, difficult tasks,
repetitive motion tasks, poor equipment access
or egress, exposure to hot surface [ > 140?F],
dust hazards, and others.)?

10.2 Have adequate provisions been specified for the

safe handling and sampling of corrosive, toxic,
carcinogenic, teratogenic, or otherwise
hazardous materials?

10.3 Have personnel safety devices (showers, eye

baths, fall prevention, breathing air systems)
been specified?

10.4 Will all asbestos-containing insulation be

removed/repaired in accordance with plant
requirements?

10.5 Will secondary surfaces (grating, slip protection

coatings) be provided where freezing or slippery
materials are handled?

10.6 Has confined space entry (including electrical

equipment) been adequately addressed in this
design?
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10.7 Has the design included adequate

walking/working surfaces in accordance with
OSHA standards and plant requirements?

10.8 Is potable water kept physically separated from

process usage?

11. WASTE WATER TREATMENT & SPILL

PREVENTION

11.1 Does this design address the potential for spills,

releases, compatibility and flammability?

11.2 Has the Environmental Health and Safety

Department (EHS) been notified of any new
waste stream sources or increased quantities
from existing sources?

11.3 Has EHS evaluated waste streams for impact on

Plant Waste Water Treatment Facilities?
(Compatibility with existing plant waste
treatment system capabilities, required
provisions for RCRA hazardous waste chemicals,
proper notification of governmental agencies,
effect on EHS operations personnel, effect on
discharges to the Publicly Owned Treatment
Work(s) (POTW) or river, and others.)

11.4 Will diking, draining, curbing, and special

protective surface coatings be adequate to
contain leaks and the worst case spill scenario?

12. SOLID & LIQUID WASTE

12.1 Has at-source waste minimization been

adequately addressed?

12.2 Have adequate provisions been made for

disposal of all wastes (including drums, bags,
filter elements, liquid residues, asbestos
containing insulation, PCBs, contaminated soil,
demolition rubble and processing equipment)?
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12.3 Have waste streams intended for disposal in the

boilers been reviewed by the EHS department?

12.4 Have the following change scenarios been

considered for possible RCRA applicability?

a. Creation of a new hazardous waste.

b. Change in composition of an existing

hazardous waste.

c. Modifications of a facility in hazardous or solid

waste service. If any of the above change
scenarios are about to happen, contact the plant
EHS department immediately for an in-depth
examination of RCRA issues. Provide
documentation of any concerns and their
resolution.

13. AIR EMISSIONS

13.1 1. Have the following change scenarios been

considered for possible air emission
applicability?

a. Increase in potential emissions of volatile

organic compound

b. New emissions of hazardous air pollutants

c. Increase in potential emissions of hazardous

air pollutants

d. Change of service for equipment

e. Composition change in existing emissions

f. Addition of new emission points (including

fugitive sources such as valves and relief
devices) or physical change in existing emission
points or monitored points. If any of the above
change scenarios are about to happen, contact
the plant EHS department immediately for an in-
depth examination of permit issues. Provide
documentation of any concerns and their
resolution.
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13.2 Have any increases in air emissions of

flammable, toxic, corrosive, reactive or
otherwise hazardous chemicals been identified,
quantified and communicated to the plant EHS
department (to obtain necessary permitting,
identify control devices being used, and others)?

13.3 Has the change been reviewed to determine if it

is subject to any requirements to recalculate
Toxic Release Inventory (TRI), reevaluate
control device efficiency, or otherwise manage
the change under state or federal requirements?

14. PROCESS EQUIPMENT

14.1 Has a pressure vessel engineer reviewed the

design/repair specifications and considerations
for new, altered or repaired equipment?

14.2 Have the appropriate welding procedure(s)

been identified?

14.3 Has spare equipment been provided where

needed for safety?

14.4 Have appropriate materials of construction been

considered for compatibility, corrosion
resistance and any GMP requirements?
(Consider 0-rings, gaskets, diaphragms, and
others.)

14.5 Has the documentation for piping and

equipment been appropriately updated?

15. COMPUTER SOFTWARE AND SYSTEMS

15.1 Are adequate safeguards in place to ensure the

process is controlled within the safe operating
envelope?

15.2 Is the fail-safe condition of controllers

adequate?
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16. OTHER SAFETY CONSIDERATIONS

16.1 Will adequate design provisions exist for cleanup

and preparation of equipment for maintenance
of equipment/piping/control systems (including
lockout of all energy sources and double
isolation where required)?

16.2 Have the consequences of loss of any utility

been adequately addressed?

16.3 Has cathodic protection, electrical continuity

and electronic grounding been adequately
addressed?

16.4 Has necessary structural analysis been

performed?

16.5 Will adequate provisions be made to ensure

equipment idled by this change is maintained in
a safe condition?

16.6 Has a change in utility consumption been

properly communicated?

16.7 Has the design included the need for labeling

including equipment apparatus numbers,
identity, content, direction of flow, and others?

16.8 Has the design included requirements for

adequate area lighting?

16.9 Has the design of the equipment included

adequate room and clearance for proper
maintenance?

17. OTHER

17.1

17.2
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Appendix III: PSSR CHECKLIST AFTER TURNAROUND/ SHUTDOWN

Pre-startup Safety Review Checklist

Inspection Date:

Department/Area:

Title/Equipment:

HSE Group Signatures:

Process Operation Group Signatures:

Maintenance Group Signatures:

(Mechanical/Electrical/Instrumentation)

Inspection/ Corrosion Group Signatures:

Others Signatures:
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Checklist Item Details (reference category / Responsibility Complete

No. item no.)
Sign & Date

Category A Action Items - Items to be completed BEFORE authorization and start-up

1.

2.

Category B Action Items - Items to be completed AFTER start-up

1.

2.

3.

4.

5.

6.

7.

8.

Area Authority Approval for Start-up:

It is accepted to start-up the equipment, as the pending items will not have effect on
operating safely.

Authorized: Facility/Equipment Owner Signature: Date

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PSSR ITEM CATEGORY/ITEM TO ASSESS (Yes / Item Remarks

NO. No / Category
NA) (A/B)

1. Remove all unnecessary maintenance

materials from plant including the
following:

1.1 Have ALL Unneeded staging/scaffolding have

been removed from the site?

1.2 Have ALL Debris: tags, insulation, gaskets and

other debris have been removed?

1.3 Have ALL Hydro-test equipment, temporary

hoses, and all other temporary related
equipment have been removed?

1.4 Have ALL Temporary piping connections have

been removed?

1.5 Have ALL test gauges have been replaced?

2. Firefighting/ Fire detection system

2.1 Fire/Gas Detection system

Have the Components of Fire/ Gas Detection

system been put in service and are ready for any
demand?

2.2 Emergency shutdown and interlock system

Have the Components of emergency shutdown

and interlock systems been put in service and
are ready for any demand?

2.3 Have the Components of Fire Fighting system

inspected using a checklist?

Have missing or inoperable equipment been

replaced?
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2.4 Are safety showers and eye wash stations

adequately working and in their original right
siting?

2.5 Pressure Relief Devices (PRD&PSV)

Have all (PRD&PSV) in the unit been checked to

be calibrated, certified, re-assembled and put in
service ready for any demand?

3. General conformity check & Field

verification

3.1 Have hydro-test/Leak Tests been performed

successfully for all maintained equipment?
Have Leak Tests been performed successfully
for all re-assembled parts of the unit?

3.2 Have All purging, flushing, draining, and pigging

been completed?

3.3 Physical check inside all vessels before boxing

up has been performed?

3.4 Correct thermal insulation reinstated where

required?

3.5 Lining up according to P&ID has been done?

3.6 De-blinding activities:

Have all de-blinding activities been performance

and re-checked as per blinding lists and
procedure?

3.7 Have all walkways, platforms, handrails,

stairways been checked to be good lightened
and safe for use?

Are swing gates or chains installed at the top of

ladders and/or on access platforms?
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3.8 Have all PTWs on the unit for all departments

been closed?

Confirmation with all concerned departments

that no pending works on the unit that could
prevent start-up?

3.9 Review work list with turnaround team,

maintenance, inspection, and engineering to
assure completion of critical jobs has been
done?

3.10 Review turnaround records and verify that all

equipment sheets have been signed and
archived has been done?

3.11 Are the start-up procedures available, adequate

and updated?

3.12 Has specific process (or job task) training been

given to personnel?

3.13 Is the normal lighting adequate for normal and

maintenance operations?
Is emergency lighting working well?

3.14 Are all hot and cold surfaces, which may cause
burns, in the proximity of personnel insulated?

3.15 Are all instruments, equipment and piping

adequately labeled as before the turnaround?

3.16 Mechanical equipment has been checked for

proper alignment, lubrication, and rotation and
functional?

4. piping

4.1 Piping is routed according to the P&ID and

isometric & Valves are installed and orientated
correctly?
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4.2 Piping and equipment have been inspected for

damage, debris, integrity, and cathodic
protection anodes installed?

4.3 Flange installations (golden flanges) have been

inspected for proper bolting, gaskets, isolation
kits, and restriction orifices?

4.4 All filters, screens, and strainers (temporary or

permanent) are properly located and installed.

4.5 All block valves on the relief systems have been

locked open?

4.6 Locked open and locked closed valves have

been inspected and are properly secured in
their intended position. The locked open/locked
closed register has been updated and
approved?

5. Instrumentation

5.1 All bypasses and jumpers on control or safety

circuits have been removed?

5.2 The fire and gas detection systems have been

inspected and tested and are in auto mode?

5.3 All instruments loops checked. Records

available

5.4 All control valves stroke properly and fail in

proper position (fail close or fail open), records
available?

5.5 All valves are opened to instrument bridles?

5.6 All tubing and tubing fittings have been

inspected for proper fit-up and leakage?

5.7 PLC logic tested and documentation has been

completed?
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5.8 Reliability of power supply to DCS/ other panel

checked & proper earthing ensured.

5.9 Field process control valves set points are ok?

6. ELECTRICAL SAFETY

6.1 Are all live parts adequately enclosed to

prevent access?

6.2 Electrical equipment rotates properly and

heaters are connected.

6.3 Grounding and bonding for All equipment and

structures have been tested and comply

with corporate and local standards/legislation?

6.4 Electrical relays, circuit breakers, transformers,

lighting and emergency power systems
(including UPS) have been inspected and
tested?

6.5 Auto changeover of feeders checked?

6.6 Electrical power load shedding schemes

finalized & tried where possible?

7. PROCESS VENTS

7.1 Flammable liquid breather vents provided with

flame arrestors or conservation vents?

7.2 Pressure gauge or other indicator provided

between rupture disc and relief valve where a
disc is installed below a relief valve?

7.3 Venting to a safe location confirmed?

7.4 Excessive length of flame arrestors?

7.5 Provisions such as drain holes to prevent

accumulation of rainwater in discharge piping?
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8.0 OTHER

8.1

8.2
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Appendix IV: PSSR Auditing Questions

NO. Question Answer

1 Have PSSRs been performed for new facilities?

2 Have PSSRs been conducted for modified facilities when the

modification is significant enough to require a change in the
process safety information?

3 Has a PSSR been performed prior to the introduction of highly

hazardous chemicals to a process?

4 Have PSSRs confirmed that construction and equipment is in

accordance with design specification?

5 Have PSSRs confirmed that safety, operating, maintenance,

and emergency procedures are in place and are adequate?

6 For new facilities, have PSSRs confirmed that PHAs have been
performed and recommendations have been resolved or
implemented before startup?

7 Have PSSRs confirmed that modified facilities meet the

requirements contained in the MOC program?

8 Have PSSRs have confirmed that training of each employee

involved in operating a modified process has been
completed?

9 For each new covered process, has the facility conducted a

safety review of the design for new equipment prior to
construction and documents that the design of the covered
process follows design and operating standards as reflected
in the process safety information?

10 Has a written report been prepared for each safety review

performed for a new covered process?

11 Has the safety review design report included the following?

• The date of the report and an identification of the covered
process, the process safety information, and standard
operating-procedures has been reviewed?
• An identification of the codes and standards upon which
the covered process design and operations were based?
• The names of the persons who performed the safety
review?
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• The deviations from the design and operating codes and

standards that were found with an appropriate description
of the resolution of each?

12 For each new covered process or modified covered process,

has the owner or operator conducted and documented a pre-
startup safety review prior to placing the covered process into
service?

13 Has a written report been prepared for each pre-startup

safety review performed for a new or modified covered
process?

14 Has the pre-startup safety review report included the

following?
• The date of the report and an identification of the covered
process?
• Documentation that: 1) the installation has been made in
accordance with the approved design, 2) safety, operating,
maintenance, and emergency procedures are in place and
adequate, 3) for new stationary sources that a PHA has been
performed and the PHA recommendations have been
resolved or implemented before startup and all the
requirements of the MOC procedure have been satisfied, and
4) operators have been trained have been completed prior to
the startup of the new or modified covered process?

15 In addition to the requirements in the OSHA PSM Standard

and EPA RMP Rule, has the Pre-Startup Safety Review
involved employees with expertise in process operations and
engineering? Have the employees been selected based upon
their experience and understanding of the process systems
being evaluated?

16 Is there is procedure in place that applies to the following

situations?
• Temporary shutdowns (e.g., as precautionary measure
such as due to an impending hurricane)?
• Maintenance turnarounds (with or without modifications)?
• Extended shutdowns (with or without modifications), e.g.,
due to business reasons?

17 Is initial/periodic refresher training on PSSR procedures

provided to affected personnel?
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18 Are decisions and actions resulting from the PSSR

communicated to appropriate personnel?

19 Are follow-up actions resulting from ORs tracked to

completion, including those not required prior to startup?

20 Do pre-startup reviews confirm that the following criteria are

met?
• Manufacturer recommendations and instructions have been
reviewed?
• Safety, environmental, operating, maintenance, and
emergency procedures are in place and adequate?
• Safety and environmental information has been updated?
• Safe work practices have been reviewed and updated as
necessary?