化工厂常用PSSR检查表.doc

化工厂常用PSSR检查表
PSSR Checklist Example A-1
PSSR清单示例A-1
Description of System/Area Under Review
所审查系统/区域的描述
Date
日期
Time
时间

List of Participants
参与者名单
Circulation: those present plus…
传阅：参加人员加上

Comments
讨论

Item
No.
序号
Recommendation
(Type Action Below or ‘not applicable’)

建议（请填写下列行动项或注明“不适用”）
Department / Responsible
Person
部门/责任人
Completed
Date
完成日期
1.
Review HAZOP list for applicable actions
查看HAZOP列表看相关行动项是否解决

2.
Review CHAZOP list for applicable actions
查看CHAZOP列表看相关行动项是否解决

3.
Review punch list for applicable actions.
查看剩余工作清单看相关行动项是否解决

4.
Noise level monitoring (document)
噪音等级监测（文件）

5.
Exposure monitoring (document)
操作人员暴露风险监测（文件）

6.
Emissions permits
排放许可

7.
Other operating permits
其他允许的行动

System Checkout Items
系统检查项目
系统检查条目

8.
Complete/document quality assurance program:
完成质量保证体系并建立了文档

a) Received equipment=purchased
收到的设备=购买的设备

b) Adherence to design drawings/specifications
采用的设计规范

c) Materials of construction
施工材料

d) Workmanship
工艺技术

.
Equipment components checkout/commissioning (document)
设备部件检查/调试（文件）

9.
Loop and interlock/permissive/alarm: set point adjustment and testing (document results)
回路和联锁/许可/报警：设置点调整和测试（文档记录）

10.
Instrument calibrations done and documented
仪表校订完成并记录

11.
Validation protocol developed, approved and executed
制定、批准和执行的验证协议

12.
Pressure testing done and documented
压力测试完成并记录

13.
System cleaned and flushed
系统已完成清扫、冲洗

14.
Fire protections systems inspected, acceptance-tested documentation provided
消防系统已检查，并有测试、验收记录

15.
Ventilation systems balanced
通风系统已平衡

16.
Performance checkout of local exhaust systems
局部排气系统的性能检测

17.
Vibration measurements/documentation
振动测量记录

18.
Field radiography done and documented as required
现场放射性物质检测已完成并记录

19.
Baseline data, such as thickness readings for pressure vessels/piping
基础数据，如压力容器/管线的壁厚

20.
Other baseline data
其他基础数据

21.
NDT reports
无损检测报告

22.
Water batching (document)

配水（记录）

Engineering Design Documentation
工程设计资料

23.
Narrative of control philosophy/Sequence of operations documentation
操作控制原理/操作顺序的说明资料

24.
Instrument index
仪表索引

25.
Instrument loop diagrams
仪表回路图

26.
Interlock (safety & non-safety) descriptions
联锁（安全和非安全）描述

27.
As-built drawings: P&IDs, electrical, piping, mechanical
竣工图：P＆ID图，电气图，配管图，机械图

28.
Tabulation of process alarms, interlocks/permissive descriptions and trips with settings (P&ID)
工艺报警表、联锁/许可说明表和带设定值(P&ID)的跳转表

29.
Review and approval of fire protections systems design
消防系统设计的审查和许可

30.
Piping specifications (P&I/mechanical drawings)
配管图（P＆I图 /机械图）

31.
Pressure relief device sizing calculations
安全阀规格的选定计算

32.
ASME code pressure vessels U-1 data sheets (to Maintenance)
压力容器ASME代码U-1数据表（用于维修）

33.
Reference codes/standards for facility design
装置设计的参考规范/标准

34.
Reference codes/standards for facility installation
设备安装的参考规范/标准

35.
Design codes for specific equipment
特殊设备的设计规范

36.
Welder certification
焊工资格证书

37.
NDT certification
无损检测证书

38.
Electrical classification drawings
电器分类图

39.
Electrician certification for classified areas
特定施工区域的电工资格证书

Maintenance Items
维修项目

40.
Spare parts lists developed
List equipment:
备品备件清单并附
设备清单

41.
Stock required spare parts
备品备件所需储存设施

42.
Equipment manuals/specifications to Maintenance and Operating Department
维修和操作部门的设备手册/说明

43.
Vendor prints
供应商提供的印刷资料

44.
Submit preventive maintenance requests (PM’s)
提交的预防性维修要求

45.
Service contracts in place
服务合同已签订

46.
Train maintenance personnel and document
培训维修人员和相关培训资料

Operational Items
生产项目

47.
Develop SOP and special procedures – incorporate safety and operational issues:
编写标准操作规程（SOP）及特殊操作规程——考虑了操作风险和可操作性问题

48.
Complete change control authorizations
完成变更控制授权

49.
Develop/issue operating procedures:
制定/颁布下列操作规程

a) Initial start-up
初次开车

b) Normal start-up
正常开车

c) Normal operation
正常操作

d) Normal shutdown
正常停车

e) Emergency operations including emergency shutdown
包括紧急停车的应急操作

f) Start-up following emergency shutdown
紧急停车后开车

g) Start-up following turnaround
大修后开车

h) Non-routine procedures (equipment clean-out, equipment preparation for maintenance)
非常规程序（设备清理、设备维修准备）

i) Auxiliary equipment operation
辅助设备的操作

50.
Train operating personnel and document
培训操作人员和相关培训资料

51.
Provide technical coverage
技术服务范围

52.
What is the probability of containment failure? What are the subsequent consequences? Review spill containment, rainwater runoff and fire water containment.
防泄漏设施的失效概率是多少？失效的后果是什么？审查防泄漏设施、雨水流量和消防水容量

Electrical Issues
电气问题

53.
Panel access, clearance around panel, keys, etc.
配电盘的通道、配电盘周围的间隙、钥匙等

54.
Cable entry section – glanding, housekeeping and other issues
电缆接入部分—密封、保洁及其他问题

55.
Panel power source identified? Multiple feeds?
配电盘电源的标识？多源供电？

56.
Space heaters required?
需要空间加热器吗？

57.
Lighting in panels
配电盘里的照明

58.
Canopies etc. for outdoor panels
用于室外配电盘的雨棚等

59.
Protection settings available?
有保护设置吗？

60.
Panel board schedules
配电盘面板清单

61.
Spare capacity available?
有备用容量吗？

62.
PPE available? HV mats, gloves
有个人防护用品吗？有高压绝缘垫吗? 有高压绝缘手套吗?

63.
Emergency/Standby power required?
有应急/备用电源吗？

64.
VSD settings available – factory/commissioning
变频器设置—工厂/调试

65.
Room access, permitting, maintainability, ingress/egress of equipment

房间通道、许可证、可维修性、设备的进出通道

66.
Pockets for drawings in panels?
配电盘的图纸集

67.
Voltage warning labels?
电压警告标签

68.
Ventilation sufficient?
通风充足吗？

69.
Suitability for area - IP rating, GMP suitability, hazardous area classification.
区域适宜性——国际防护等级、GMP适宜性、危险区域分类

- Relief Devices
- 泄放设备

70.
Are there standard markings on the P&ID?
在P&ID图上有标准代号吗？

71.
Do relief lines vent to a safe location?
放空线排放到一个安全地点吗？

72.
Are relief lines and relief devices secured and adequately sized?
放空线和泄放设备安全吗?尺寸足够大吗？

73.
Are there any isolation valves which will inhibit operation of relief valves if closed? If YES, nominate Operations to monitor. If NO, record no.
有处于关闭状态会抑制放空阀操作的隔离阀吗？如果有，请指定操作人员对其进行监视。如果没有，记录无

74.
Is there a standard operating procedure for relief devices in place?
现场有泄放设备的标准操作规程吗？

- For Field Verification
- 现场确认

75.
Is lighting sufficient?
照明充足吗？

76.
Is emergency lighting sufficient?
应急照明充足吗？

77.
Are steam pipes, valves, or traps situated within proximity of people insulated?
位于人接近范围内的蒸汽管线、阀门或疏水器被隔离了吗？

78.
Is all instrumentation identified and tagged?
所有的仪表都有标识和挂牌了吗？

79.
Is there any rusted or damaged equipment?
有任何生锈或损坏的设备吗？

80.
Are swing gates installed on top of ladders or on access platforms?
在梯子顶部或平台通道上安装了止回门吗？

81.
Review edge protection on platforms and heights. Will it protect personnel and equipment? Is access adequate?
检查平台和高处的边缘保护。它能保护人员和设备吗？通道足够吗？

82.
Do safety showers provide a hazard to people (slips), product (contamination of systems), or ingress to electrical switchgear or equipment?
安全喷淋对人(滑跤的危险)、产品（系统的污染）或内部的电气开关柜或设备产生危险了吗？

83.
Are safety showers supplied from tempered water?
安全淋浴供应热水吗？

84.
Is chemical dosing within a safe proximity of people and product?
化学品操作是在人和产品安全接近范围内吗？

85.
Label all pipe lines
标识所有的管线

86.
Label all electric switches, disconnects, MCCs, control panels, cables, etc.
标记所有的电气开关、中断器、电动机控制器、控制盘和电缆

87.
Label vessels (material, hazard warnings)
List:
标记容器（材料、危险警告）的清单

88.
Seal wall penetrations
密封墙壁的渗透

89.
Pour conduit seals
灌注导管的密封

90.
Install fire extinguishers

91.
Evacuation routes posted

92.
Install appropriate area signs

93.
Is all scaffolding and equipment removed; is general housekeeping acceptable?

94.
If there is potential for entrapment or exposure, has an E-Stop been provided?

95.
If full guarding is in place, has a lockable isolation device been provided?

96.
Pest control required in room/building?

97.
MSDS sheets required?

98.
Sprinklers in rooms?

99.
Single point of failure condition? Has it been identified? – Record.

PSSR Checklist Example A-2
Pre-startup Safety Review Checklist
Inspection Date:

Department/Area:

Project Number:

Title/Equipment:

Signatures below indicate acceptance that the equipment or project is safe and satisfactory to start-up with the exceptions noted.
Engineering / Maintenance
Date
EHS Group
Date
QA Group
Date
Manufacturing / Operations
Date
Project Engineer
Date
Process Engineering
Date
Checklist
Item No.
Details (reference category/item no.)
Responsibility
Complete
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.

12.

Sign below only when all punch list “before start-up” items are completed
Authorized:
Facility/Equipment Owner Signature:
Date

PSSR ITEM NO.
CATEGORY/ITEM TO ASSESS
Not
Applicable
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
Have bump/trip hazards been properly identified and adequately marked?
Have all sharp edges been removed?

1.1.7
Has proper guarding, handrails/barriers, been provided to prevent falls?

1.1.8
Have all hot/cold surfaces been adequately guarded to prevent burns?
Are all cold surfaces adequately insulated to prevent condensation drips (slip hazards)?

1.1.9
Are Safety Showers and Eye Wash facilities provided and adequately marked?
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?

1.1.10
Has sufficient lighting been provided so that operation, servicing, maintenance, and repair of the facilities can be carried out safely?

1.1.11
Are notices, dials, screens, etc. for providing operational instructions, safety warnings, and emergency information provided, if required, and positioned so that they are clearly visible and easily read?

1.1.12
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?

1.1.13
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?

1.1.14
Has 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)?

12
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?

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?
Have 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?

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?

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
Does the operation of this equipment increase the risk of Upper Limb Disorder; for example, repetitive tasks, handling operations, machine paced work and prolonged operation?

1.4
OCCUPATIONAL HEALTH

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?

1.4.3
Has the need for an Occupational Health Monitoring Programme been assessed?
Has a Monitoring Programme been scheduled?

1.4.4
Have the Operating Procedures been reviewed to take into account any additional “health hazards” which may arise from operation or maintenance of this equipment?

1.4.5
Has adequate LEV (Local Exhaust Ventilation) been installed, tested, balanced, and entered on an Inspection Schedule?