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Petrochemical Pre-Startup Safety Review (PPSR) Checklist

Contributor: Safesite Jurisdiction: OSHA

general industry
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oil, gas and petroleum

A systematic review of new or modified facilities performed at mechanical completion prior to startup or the introduction of regulated PSM/RMP chemicals. PSSRs must be performed for all new facilities/stationary sources and for modified facilities/stationary sources when the modification is significant enough to require a change in the process safety information. Complete the PSSR Checklist after mechanical completion and prior to startup of facility.

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Petrochemical Pre-Startup Safety Review (PPSR) Checklist

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Pressure/Vacuum ConsiderationSection 1 of 10 with 9 Questions

1. Has protection been provided against overpressure and vacuum and is the correct size and setting relief device been installed?

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2. Is relief device discharge piping adequately braced against reaction forces and directed away from personnel?

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3. Have weep holes or drains been provided in the discharge piping of pressure relief devices?

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4. Have block valves been installed in relief device piping? If YES are they full port valves and are they locked open?

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5. Have new safety valves and rupture discs been tagged and entered into the routine maintenance program?

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6. Have provisions for cleaning relief device piping been provided?

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7. Have pressure relief device calculations been properly documented and incorporated into the master relief device records?

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8. Have pressure relief devices been captured on safety valve lock list if required?

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9. Have pressure gauges or monitors been installed in the space between a rupture disc and pressure relief valve and is this space being monitored via operator rounds or DCS? Ensure gauge is on operator rounds checklist.

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Temperature/Reaction ConsiderationsSection 2 of 10 with 4 Questions

1. Have personnel been adequately protected from contact with hot surfaces?

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2. Has potential for instrument failure (including computer shutdown) and loss of utilities been adequately addressed?

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3. Has potential for leaks into or out of the process been adequately addressed?

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4. Has potential for improper valve set-up or operating error been adequately addressed?

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Valve, Piping, and Vessel ConsiderationsSection 3 of 10 with 17 Questions

1. Have cross-tied lines (pump headers, utility lines, etc.) been avoided where contamination, pressure, or temperature problems are likely?

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2. Has a line by line review been conducted to assure that valves, piping, and vessels are installed as specified?

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3. Are vents and drains located such that they do not create a personnel hazard?

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4. Are sample points installed and properly configure for safe sampling?

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5. Can valves and equipment be safely accessed for operation and maintenance? Do adequate provisions exist for cleanup and can all valves can be locked, blinded or disconnected?

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6. Are hoses and fittings the proper type and have bleedoffs been provided at hose connection points? Have hoses been fitted with current inspection tags? Were brittle pipe failure issues addressed?

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7. Has adequate back-flow prevention been provided and installed properly?

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8. Has appropriate testing been completed to ensure integrity of new or revised piping systems and is the piping system adequately supported or braced?

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9. Are process sight glasses, flow indicators, gauges, etc. properly armored?

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10. Have lines and vessels been clearly labeled, including flow arrows and hazard identification symbols?

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11. Has material of construction been verified to assure correct material was received and installed as per specifications? Were brittle pipe failure issues addressed?

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12. Has the testing fluid been properly flushed from the piping or vessel and all test blanks and blinds been removed?

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13. Have drawings been revised to show “as installed” condition?

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14. Have equipment and piping been registered in the inspection program with new inspection due dates included? Has baseline Mechanical Integrity Inspection been performed and documented?

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15. Have valve, piping, and equipment been pressure checked?

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16. Have stress relieving requirements been met?

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17. Has Risk Based Inspection evaluation and grouping been performed as required by N-G-MC-105?

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Rotating and Mechanical Equipment ConsiderationsSection 4 of 10 with 9 Questions

1. Have adequate equipment guards been installed and adequate provisions exist for clean-up, isolation, and lock-out of equipment to perform maintenance?

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2. Have deadhead pressure and seal leakage been considered for pumps?

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3. Has the rotation of equipment been checked to assure it is correct and the lubricants and seal fluids been properly charged?

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4. Is equipment adequately labeled?

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5. Are capacities of lifting equipment, floors, and hoists clearly displayed and visible to the operator?

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6. Are mechanical interlocks operating properly?

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7. Has stress on machinery due to piping or nozzle loading been addressed?

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8. Has the Reliability Group been notified n order to establish baseline vibration data or to add equipment to oil analysis monitoring?

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9. Have flex hoses or hoists been installed that must be added to proper inspection programs?

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Control Systems ConsiderationsSection 5 of 10 with 11 Questions

1. Are instruments and alarms provided where necessary and unnecessary alarms avoided?

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2. Has the fail safe function of valves been properly installed and tested and the actuator air supplies been valved in?

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3. Has the potential for interaction with existing controls been reviewed?

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4. Has the operation of interlocks, alarms, and control loops been verified? Have Z-devices been locked and tested?

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5. Can automatic valves be properly isolated and cleaned for servicing or removal?

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6. Have provisions been made for routine maintenance?

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7. Have instrument loop drawings, cause and effects documents, and specification sheets been updated?

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8. Have Z-devices been included on the lock list for review?

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9. Have analyzers been included in the PM program?

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10. Have SIL calculations been performed on “Z” devices as required by PA-P-EI-100?

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11. Have new Gas Chromatographs or other process stream analyzers been installed in the process that will require scheduled calibration or inspection?

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Electrical System ConsiderationsSection 6 of 10 with 11 Questions

1. Have the correct electrical classification rules been observed?

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2. Have start/stop switches and electrical switchgear been properly labeled and can electrical equipment be isolated safely by lock-out provisions for repair work?

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3. Have conduit fitting covers been installed, conduit seals poured, and electrical equipment been adequately protected from weather and corrosion?

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4. Have electrical protective relays and safety devices been checked for proper calibration?

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5. Have electrical guards been installed and indicator lights operating properly?

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6. Has ground installation been verified against construction drawings and tested per plant standard?

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7. Are ground wires available for tank trucks, rail cars, and drums (as required)?

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8. Has electrical heat tracing been properly installed, labeled, and provisions for lockout established?

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9. Is critical spare equipment fed from a separate power source?

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10. Have electrical drawings been revised to reflect “as installed” condition?

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11. Where needed are guards provided to prevent accidental tripping of switches?

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Safety/Environmental ProtectionSection 7 of 10 with 15 Questions

1. Have inert blankets, purges, sprinklers, and fire proofing been installed where specified?

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2. Has the installation created the need for relocating or adding fire extinguishers, fire monitors, safety showers, eye baths, or air packs?

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3. Is the lighting adequate?

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4. Have tripping hazards or head knockers been avoided?

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5. Do walkways and ladders provide safe access at all levels and are walking or working surfaces level, properly secured, and do they provide proper traction? Are safety gates properly installed?

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6. Does equipment layout provide safe access for operation and maintenance?

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7. Have elevated work requirements been met?

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8. Is the work area adequately ventilated where needed?

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9. Are adequate provisions made for drum and cylinder handling?

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10. Has the HAZCOM program been updated to reflect changes in chemicals? Are MSDS’s available?

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11. Do signs adequately identify work area hazards and provide proper instruction?

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12. Are exit and egress routes clearly identified?

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13. Have any new noise areas been created or existing areas been made worse?

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14. Has the system been reviewed to assure minimal personnel exposure to toxic chemicals during operation and maintenance?

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15. Can hazardous materials from spills or maintenance preparation be safely handled? Have adequate provisions been made for disposal of all wastes? Have waste lines been routed to appropriate sewers?

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Will run-off water be adequately contained if it becomes contaminated? Have all containment issues been adequately addressed?Section 8 of 10 with 4 Questions

1. Have all environmental permits been obtained? 18. VOC Equipment List update needed and provided to LDAR contractor to ensure new components are tagged and monitored?

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2. Has LDAR P&IDs been color coded with appropriate stream identification and provided to LDAR contractor and TES department as required by PA-P-BR-205?

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3. If expansion joints are being installed, have they been added to the inspection program required by PA-P-MC103?

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4. Have any site boundary isolation points been created or modified? If so, update Master Boundary Isolation documentation.

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Other ConsiderationsSection 9 of 10 with 7 Questions

1. Have all Management of Change items been completed as required by the MOC Form?

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2. Does the facility comply with all applicable engineering standards and design specifications?

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3. Were any safety problems created during construction package?

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4. Have operating procedures been written, and operating parameters established and has operator training been conducted?

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5. Have the safety and emergency procedures been updated?

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6. Has the potential impact of the change on unchanged facilities been adequately addressed?

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7. Has spare critical equipment been provided and set up in the warehouse inventory?

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Have maintenance procedures been updated?Section 10 of 10 with 7 Questions

1. Have all equipment files been updated?

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2. Have instrument/analyzer procedures been updated?

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3. Have specialty items been documented and included in the PM program?

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4. Does any new equipment installed make existing spare parts obsolete from the storeroom or other staged areas?

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5. Has Equipment Registration along with creation of Functional Location, spare parts, and preventive maintenance been completed as required by PA-P-ME101?

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6. Has MOC Coordinator updated the Control Room Master P&ID’s by attaching the redline P&ID’s to the affected master P&ID’s?

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7. Write Comments or Remarks here:

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