Pre-Startup Safety Review (PSSR) Checklist
Pre-Startup Safety Review (PSSR) Checklist
Pre-Startup Safety Review (PSSR) Checklist
(PSSR) Checklist
A PSSR inspection allows you to thoroughly review the status of employee training,
construction, equipment, and other components involved in a company change. This PSSR
checklist will help ensure that your employees are kept safe during Management of Change
(MOC). Edit this pre-startup safety review (PSSR) checklist to fit your needs.
By:
Updated:
Pre-Startup Safety
1. Have all affected personnel Yes No N/A Comments
(Operations, Maintenance, Technical,
and Supervision) received adequate
and appropriate training on the new
equipment and operating
procedures?
4. Have the PPE users been trained in Yes No N/A Comments
the use of the PPE?
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6. Have measures been taken to Yes No N/A Comments
adequately guard all dangerous parts
of this equipment?
10. Have all sharp edges been removed? Yes No N/A Comments
12. Have all hot/cold surfaces been Yes No N/A Comments
adequately guarded to prevent burns?
13. Are all cold surfaces adequately Yes No N/A Comments
insulated to prevent condensation
drips (slip hazards)?
14. Are Safety Showers and Eyewash Yes No N/A Comments
facilities provided and adequately
marked?
15. Are the Safety Showers and Eyewash Yes No N/A Comments
facilities routinely inspected?
16. Do the Safety Showers and Eyewash Yes No N/A Comments
facilities locations comply with
Corporate guidelines?
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17. Are the Safety Showers and Eyewash Yes No N/A Comments
facilities readily visible and
accessible?
18. Has sufficient lighting been provided Yes No N/A Comments
so that operation, servicing,
maintenance and repair of the
facilities can be carried out safely?
19. Are notices, dials, screens, etc. for Yes No N/A Comments
providing operational instructions,
safety warnings, and emergency
information provided, if required, and
positioned so that they are clearly
visible and easily read?
20. Have all overhead fixtures, for Yes No N/A Comments
example, pipe-hangers, pipe sleeves,
pipe sleeve covers, valve handles,
floor opening covers, etc., which
could fall or be dislodged, been
properly secured?
21. Are all of the applicable Work Permit Yes No N/A Comments
Procedures (Confined Space Entry,
Lock Out/Tag Out, Hot Work, High
Work, etc.) in place?
23. Has the re protection systems been Yes No N/A Comments
inspected by the insurance company?
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25. Is there an agreed on test and Yes No N/A Comments
inspection program for the re
protection systems (including alarm
systems)?
27. Has all access to dangerous moving Yes No N/A Comments
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?
28. Have the correct safety measures Yes No N/A Comments
been taken to prevent any risk from
hot/cold surfaces, ejection of
material, failure of parts and their
ejection, overheating/fire?
29. Has safe access been provided to the Yes No N/A Comments
equipment that requires operator and
calibration and maintenance
personnel access for normal
operations, adjustments, service,
calibration, maintenance, or repair?
30. Have slip, trip, trap, crush, Yes No N/A Comments
entanglement, fall, bump, and cut
hazards been minimized?
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31. Is the equipment provided with the Yes No N/A Comments
properly identified START/STOP and
EMERGENCY controls that are
positioned for safe operation without
hesitation, or loss of time, and
without ambiguity?
Ergonomics
33. Have the workstations, workplace, or Yes No N/A Comments
equipment been constructed so that
the need for stooping, bending
stretching, over-reaching and working
over-head during operation has been
eliminated or minimized?
34. Has the need to lift, carry, push or pull Yes No N/A Comments
heavy loads, or parts, been eliminated
to the extent possible?
35. Are all display screens, dials and Yes No N/A Comments
START/STOP/ EMERGENCY buttons
positioned so that they are readily
visible and accessible by the
operating personnel?
36. Have Visual Display Screens been Yes No N/A Comments
positioned so that interference from
glare is reduced to the minimum?
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37. Have workstations been designed Yes No N/A Comments
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.)
38. Does the operation of this equipment Yes No N/A Comments
increase the risk of Upper Limb
Disorder; for example, repetitive
tasks, handling operations, machine
paced work and prolonged operation?
Occupational Health
39. Have all health risks arising from the Yes No N/A Comments
gases, liquids, dusts, mists, biological
hazards or vapors used by, contained
in or emitted by this equipment been
assessed
40. Have the health risks been eliminated Yes No N/A Comments
or are adequate engineering controls
utilized to minimize the risks?
42. Has the need for an Occupational Yes No N/A Comments
Health Monitoring Program been
assessed?
44. Have the Operating Procedures been Yes No N/A Comments
reviewed to take into account any
additional “health hazards” which
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may arise from operation or
maintenance of this equipment?
45. Has adequate LEV (Local Exhaust Yes No N/A Comments
Ventilation) been installed, tested,
balanced, and entered on an
Inspection Schedule?
47. Are relief facilities directed to a safe Yes No N/A Comments
place away from the workplace?
48. Has a Noise Survey been considered Yes No N/A Comments
and a Noise Compliance Plan
prepared, if required?
49. Has insulation been installed and Yes No N/A Comments
identified?
50. Has all pipe work, tanks, and Yes No N/A Comments
equipment containing hazardous
materials been adequately labeled?
52. Have the hazardous effects of Yes No N/A Comments
inadvertent mixing of different
materials been considered (that is,
has a chemical interaction matrix
been prepared/updated)?
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53. Has the process design basis been Yes No N/A Comments
documented or updated?
54. Has the control philosophy and Yes No N/A Comments
sequence of operations been
documented?
55. Has the equipment design basis (for Yes No N/A Comments
example, BPF’s/P&IDs) been
documented/updated?
57. Are there any incomplete items? Yes No N/A Comments
Identify them in comments)
58. Are all relief devices shown on the Yes No N/A Comments
P&IDs?
59. Are standard markings used on the Yes No N/A Comments
relief devices?
61. Have the pressure relief device Yes No N/A Comments
calculations been provided?
62. Was DIERS technology utilized to size Yes No N/A Comments
the pressure relief devices for all
pressure vessels?
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63. Does the sizing of pressure relief Yes No N/A Comments
devices agree with the calculated
sizes?
64. Do the calculations take into the Yes No N/A Comments
downstream piping?
65. Do the relief devices vent to safe Yes No N/A Comments
locations?
67. Are there isolation valves that, if Yes No N/A Comments
closed, will inhibit the operation of
pressure relief devices?
69. Are all pressure relief devices Yes No N/A Comments
included in the Preventive
Maintenance Program?
70. Are the inspection and testing of Yes No N/A Comments
relief devices in accordance with
local regulations?
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72. Has a test authorization been Yes No N/A Comments
approved?
73. Are all action items, arising from the Yes No N/A Comments
COD, that were deemed necessary for
startup, complete?
74. Have all changes made during Yes No N/A Comments
construction been recorded and
authorized?
77. Are all action items, deemed Yes No N/A Comments
necessary by the PHA team for
start-up, complete?
78. Has the project been approved as Yes No N/A Comments
“Safe to proceed with” by the PHA
team?
79. Have checks and inspections been Yes No N/A Comments
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
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alignment and service to process
inter-connections)?
85. Data sheets for pressure equipment Yes No N/A Comments
built to ASME or equivalent codes?
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87. Non-destructive test (NDT) Yes No N/A Comments
certifications?
Mechanical Safety
91. Have spare parts listed been Yes No N/A Comments
developed and entered into the parts
ordering software program?
92. Are there adequate inventories of Yes No N/A Comments
spare parts, operating supplies and
maintenance materials?
94-106. Have inspections and tests (including regulatory requirements) for the following
equipment been included in a maintenance schedule?
94. Pressure vessels and storage tanks? Yes No N/A Comments
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96. Critical controls, interlocks (both Yes No N/A Comments
safety & non-safety), alarms and
instruments?
99. Piping systems (incl. Components, for Yes No N/A Comments
example, valves, excess flow valves,
expansion bellows) in critical service?
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105. Pumps? Yes No N/A Comments
109. Have all commissioning tests or Yes No N/A Comments
inspections been identified (for
example, pressure, or leak tests,
passivating procedures)?
Standard Operating Procedures (SOPs) Safety
110. Have standard operating Yes No N/A Comments
procedures been prepared/updated
and approved?
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112. Normal start-up? Yes No N/A Comments
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120. Safety and operational issues? Yes No N/A Comments
Task Training
122. Has specific process (or job task) Yes No N/A Comments
training been given to personnel?
124. Have all contract personnel been Yes No N/A Comments
adequately trained in appropriate:
chemical awareness, maintenance,
and operating activities and
evacuation procedures?
125. Has the alarm/interlock (safety & Yes No N/A Comments
non-safety) been classified and
designed by the Project Team? Did
the Project Team include members
of the PHA team?
126. Did the loop testing confirm that the Yes No N/A Comments
alarm/interlock (safety & non-safety)
action proved, under all conceivable
failure conditions, to be fail-safe?
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Yes No N/A Comments
127. Prior to this PSSR, has an
interlock/critical alarm Standard
Operating Procedure for testing,
through to the final element, been
prepared and reviewed/authorized by
a competent person for each new or
upgraded control system?
128. For alarms/interlocks (both safety & Yes No N/A Comments
non-safety) with more than one
software or hardware circuit, have all
possible interlock routes been
tested?
129. Has all appropriate process Yes No N/A Comments
technology been updated (for
example, interlock lists, P&IDs, logic
drawings, etc.)?
Yes No N/A Comments
130. Does your Control System
documentation adequately specify:
Yes No N/A Comments
131. All major components and their
model and serial numbers?
Yes No N/A Comments
132. All communication cables layout and
configuration?
Yes No N/A Comments
133. Any configurable or custom settings
and set-up?
Yes No N/A Comments
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Yes No N/A Comments
Environmental
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Yes No N/A Comments
141. Have adequate arrangements been
made, prior to start-up, for the
identification, classification, and safe
disposal of all waste materials?
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Yes No N/A Comments
148. Are all of the applicable Construction,
Environmental and Operating Permits
up to-date and approved?
149. Have all necessary precautions been Yes No N/A Comments
taken to ensure that the equipment is
not a source of ignition to any
flammable materials, irrespective of
their source?
150. Are reprotection facilities adequate Yes No N/A Comments
for example, re extinguishers, re
walls, sprinkler systems, Alarm
Boxes, etc.)?
151. Are Emergency Escape Routes, Yes No N/A Comments
including ladders, adequate and
properly signposted?
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156. Has an Electrical Safety Checklist Yes No N/A Comments
(Acceptance of Electrical
Installations) been completed by a
competent personnel?
157. Has the equipment been properly Yes No N/A Comments
installed and constructed to
Corporate guidelines and local
legislation, and does it meet any
special installation requirements
noted on the manufacturer’s
certificate?
158. Has equipment been designed and Yes No N/A Comments
purchased for the conditions under
which it will operate (for example,
hazardous areas)?
Yes No N/A Comments
159. Are all live parts adequately enclosed
to prevent access?
162. Are First Aid Stations, single line Yes No N/A Comments
drawings and PPE requirements
available in Motor Control Centers
(MCC), Electrical Control Rooms
(ECR)/Sub-stations, as appropriate?
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163. Have all relevant documentation and Yes No N/A Comments
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?
164. Have all new Substation Breakers, Yes No N/A Comments
MCC isolators, starters or other
appropriate equipment been
registered on to the Site Inspection
Schedule?
Field Verification
168. Are all hot and cold surfaces, which Yes No N/A Comments
may cause burns, in the proximity of
personnel insulated?
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Yes No N/A Comments
170. Is there any rusted and/or damaged
equipment?
172. Are there any gaps between Yes No N/A Comments
platforms and equipment that could
create a foot hazard?
175. Are safety showers and eyewash Yes No N/A Comments
stations adequately marked and
readily visible?
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Yes No N/A Comments
179. Is all the equipment clearly labeled?
186. Are emergency stops provided where Yes No N/A Comments
there is a potential for entrapment or
exposure?
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Yes No N/A Comments
189. Is all required equipment guarding
installed
190. Does all the applicable equipment Yes No N/A Comments
have the required CE marking
displayed?
Completion
Yes No N/A Comments
195. Safe and ready for
commissioning/startup?
Inspector Signature:
Approval Signature:
Approval Signature:
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