MAJOR Pre-Startup Safety Review (PSSR) Checklist

FACILITY:

IVANHOE - ORION ENGINEERED CARBONS

MOC NUMBER:
MOC TITLE:
Item

Question

Group
PIPING

Piping is routed and valved according to the P&ID.

Construction

Inspect valves, flanges and spec breaks to confirm proper pressure rating and compatibility.

Construction

Piping and equipment has been inspected for damage, debris, integrity, and anodes

Operations

All critical piping systems have hydro, pneumatic or non-destructive testing completed and QA documentation has been
reviewed.
Relief systems, PSV's, PCV's, vent piping, flare stacks, and vent booms are installed per construction dwgs.

Construction

Operations

All permanent blinds are in place; all temporary blinds have been removed. The blind list has been reviewed and
approved.
Flange installations have been inspected for proper bolting, gaskets, isolation kits, and restriction orifices.

All purging, flushing, draining, and pickling complete.

Operations

All drains and sewers have been inspected for plugs and covers.

Operations

10

Proper installation, operation and orientation of valves (process, instrumentation, utility...) have been ensured.

Construction

11

All filters, screens, and strainers (temporary or permanent) are properly located and installed.

Construction

12

Piping systems have been reviewed allowing for equipment/facility blowdown and isolation

Construction

13

Vents have spark / detonation arrestors, where appropriate.

Engineering

14

The integrity of all thermowells and bull plugs have been inspected.

Construction

15

Exhaust lines / vents are properly located away from air intakes, air conditioners, fans, sources of ignition, etc.

Construction

16

All block valves on the relief systems have been locked or car sealed open and are in a functional state

Construction

17

Lock open and lock closed valves have been inspected and are properly secured in their intended position.

Construction

18

All block valves have been reviewed for normal position (norm. open or closed) and handle has full travel.

Construction

19

All fail safe valves have been reviewed for proper action (fail open, fail close, fail unchanged); and location.

Construction

20

Structural steel installed to engineering design specifications.

Engineering

21

Supports required meet design structural engineering standards.

Engineering

22

All equipment meets design specifications.

Engineering

23

Construction

24

Mechanical equipment has been checked for proper alignment, lubrication, and rotation; functional checkouts have been
performed on equipment and controls.
All equipment has been filled with proper fluids to the appropriate level and charged as necessary.

25

Adequate spare parts are available.

Operations

26

Electrical Motors (check for proper rotation and heaters are connected).

Construction

27

All equipment and structures grounded and tested.

Operations

28

Electrical relays, circuit breakers, transformers, lighting and emergency power systems inspected and tested.

Construction

29

Controllers and disconnects are labeled if the device being controlled is not obvious.

Construction

30

All electrical equipment installed to design specifications.

Construction

31

Construction

33

All electrical seals have been packed and poured; all explosion-proof boxes, conduit covers are properly secured and all
electrical connections tightened and checked.
Any equipment and associated breaker panels not to be used or not available for use are out of service. All lockouts are
flagged, tagged and listed.
Rotating equipment trip points, especially over speed, have been checked and tested.

34

The UPS and/or emergency power systems have been tested.

Construction

5
6

Construction

Construction

CIVIL

MECHANICAL

Construction

ELECTRICAL

32

Construction
Construction

/ NA

Initials

35

INSTRUMENTATION
All instrumentation installed to engineering design specifications (API RP 14C)

Engineering

36

All electrical and pneumatic loop checks completed.

Operations

37

Interlocks (Electrical and Mechanical) have been reviewed and tested for proper operation.

Operations

38

All tubing and tubing fittings have been inspected for proper fit-up and leakage.

Operations

39

All instruments weatherproofed.

Operations

40

Emergency equip. alarms, communication equip, and shutdown devices calibrated, tested, documented and activated.

Operations

41

The fire and gas detection systems have been inspected and tested and are in auto mode.

Operations

42

All bypasses and jumpers on control or safety circuits have been removed.

Operations

43

PLC logic tested and documentation completed.

Engineering

44

Backup batteries at full charge.

Operations

46

HEALTH AND SAFETY

47

Fire detection system has been reviewed for proper detector location and correct response / action.

Operations

48

All safeguards including signs (DANGER, HIGH VOLTAGE, KEEP OUT, HEARING PROTECTION REQUIRED), chains,
safety equipment boxes, PPE boxes, etc. are installed and adequately stocked.
Area has been cleared of construction equipment, surplus equipment, combustible materials, extraneous tools, unused
parts, scaffolding and empty drums.

Operations

45

49

Operations
Operations

Construction

50

DOCUMENTATION
All applicable permits and approvals have been received from regulatory agencies (MMS / USCG)

Engineering

51

Emergency response and evacuation procedures/plans updated, communicated, and in place.

Operations

52

Hazard analysis recommendations have been addressed and implemented.

Engineering

53

Flare System /PSV/ Ventilation System design basis updated.

Engineering

54

Safety information is complete and in place.

Operations

55

A start-up plan has been prepared and applied.

Operations

56

Written startup, operating and shutdown procedures are in place (SOPs).

Engineering

57

Training of affected personnel has been completed (operations, maintenance, emergency response, etc.).

Operations

58

All construction punch list items have been reviewed and completed

Construction

59

Piping and Instrumentation Diagrams (P&ID's) redlined.

Engineering

60

Process Flow Diagrams (PFD's) redlined.

Engineering

61

Process and Safety Flow Diagrams (PSFDS) redlined.

Engineering

62

SAFE chart redlined.

Engineering

63

Fire and Safety Equipment Locations Plans redlined

Engineering

64

Electrical Area Classification Plan drawings redlined.

Engineering

65

Electrical One-line drawings redlined.

Engineering

66

Structural and Isometric drawings redlined.

Engineering

67

MSDS files updated.

Operations

68

Weight Management Program impacts addressed.

Engineering

69

PS/IM program updated.

Engineering

70

Inspections and Maintenance requirements addressed in MAXIMO.

Engineering

71

All applicable vendor data updated. (i.e., mechanical, electrical, instrument, etc.)

Engineering

72

Pressure Equipment Pre Commissioning Form completed and sent to Operating Centre IM Specialist Form

Construction

APPROVALS

All Responses reviewed by

Title/Position

Name

Date

Title/Position

Name

Date

Title/Position

Name

Date

Authorization to Startup