Process Safety Fundamentals (PSF) Questionnaire

The objective of this questionnaire is to collect information on the main issues that can prevent compliance with process safety fundamentals, giving hints to the
management about how address the issues.
If any question does not apply to your job/duties, please mark it as N.A. (not applicable).

Use the Notes field to insert any considerations, especially if the answer is NO or there are actions that should be done but are not done.

1. Please indicate your Facility/Plant/Department:

2. Please indicate your worker group:

Superintendent / Foreman

Supervisor

Lead Operator/ Lead Technician

Operator/ Technician

Engineer
PSF 1 – Verify process line-up condition before start-up

Objective:
 minimize spills of hazardous materials or involuntary mixing, which occur when the line is not ready for correct operation due to open disconnections, incorrect
alignments of valves or vessels/tanks, improperly tightened flanges

To be verified in the field:

 physically walk along the lines before starting work
 compare P&ID and valve positions
PSF 1 – Verify process line-up condition before start-up

# Question Answer Notes/Other Considerations

During your activities, can you always determine the correct __ Yes (specify how)
position of the valves or other equipment? __ No (specify location)
If not, specify the area/location.

Do you verify the line-up on P&IDs and the real line-up in __ Never
the plant location? __ When my supervisors asks me
__ Always before the job
__ Always before the job and when there is spare time

How do you inform your management about the changes in __ I do not report
the position of the valves/lines, which are not indicated on __ I tell my supervisor
the P&IDs? __ I mark up the P&ID and provide it to my supervisor
__ We have a procedure for reporting P&ID discrepancies

Do you check the condition of all drains and bleeders before __ All drain/bleeder valves are checked before start-up
equipment start-up? __ Only those involved in the maintenance work
__ Only those indicated in the start-up checklist
__ Only those requested by the supervisor/lead

Do you need additional/improved checklists for verification __ Yes

of equipment status before start-up? __ No
PSF 2 - Verify connections tightness before returning to service

Objective:
 prevent releases from flanges or other types of seals of process equipment

To be verified on site:
 correct execution of the tightening procedure (if the job is relevant)
 execution of leak tests (e.g. visual inspection, preventive pressing) and analysis of the results
 monitoring of the areas concerned, during the restart phase
PSF 2 - Verify connections tightness before returning to service

# Question Answer Notes/Other Considerations

Do you carry out tightening/tightness check of bolted joints __ Yes

and threaded connections as part of your job duties? __ No

If carrying out tightening/tightness check is part of your job __ It is not part of my duties
duties, when did you receive last training on this topic? __ Never
__ At the beginning of the job
__ At each technical or procedural modification
__ Other (specify)

Is there a procedure which describes the requirements for __ Yes

tightening/tightness check of bolted joints and threaded __ No
connections? __ My job does not involve knowledge of it

Is it always possible to perform the leak test? __ Yes

If not, specify when/where it is not possible. __ No (specify)

Is it always possible to verify (on field and DCS) that all __ Yes
instrumentation is properly connected before equipment __ No (specify)
start-up?
If not, specify when/where it is not possible.

Are operators always present on-site during the start-up of __ Always present
process equipment for monitoring and responding to any __ Not always present
deviations? __ Never present
PSF 3 – Report & take interim mitigating measures for impaired Safety & Environmental Critical Elements (SECE)

Objective:
 bring attention to those parts of the plant whose failure could cause or contribute substantially to a major accident, or whose purpose is to prevent or limit the
effect of a major accident (safety and environment critical elements - SECE)

To be verified on site:
 identify SECEs and visually verify their correct functioning
PSF 3 – Report & take interim mitigating measures for impaired Safety & Environmental Critical Elements (SECE)

# Question Answer Notes/Other Considerations

Do you know which equipment is considered safety critical __ I don’t know what is a safety critical element
(SECE) at your work site? __ All equipment is safety critical
__ I know in general
__ I know exactly which equipment is safety critical in my work
area

Are training activities on SECE carried out (definition, __ Yes

identification, updating, etc.)? __ No

What are your actions if you find a damaged SECE, e.g. __ I cannot do anything
while performing the maintenance activity in your area? __ I try to fix it myself
__ I report to my line manager
__ Other (specify)

Are there SECEs in your area that require shutdown in case __ I don’t know
of unavailability? __ No, there aren’t
__ Yes, there are and I know them (specify)

Do you receive information about control measures that __ Always

should be taken and maintained in case of a faulty SECE? __ Often
__ Sometimes
__ Rarely
__ Never
PSF 4 - Provide safe isolation before starting a maintenance job

Objective:
 prevent releases from single valves or process equipment because they are not completely segregated during the preliminary works to maintenance (e.g.
blinding, segregation, etc.)

To be verified in the field:

 compliance of the mechanical isolation method with the requirements of the procedure
 need for double barrier and supervision
PSF 4 - Provide safe isolation before starting a maintenance job
# Question Answer Notes/Other Considerations

Do you check the tightness of the valves to be closed to __ Always

achieve isolation? __ Often
__ Sometimes
__ Rarely
__ Never

Are there open drain/vent lines to atmosphere which are __ No

not provided with two barriers (e.g. valve and plug)? __ Yes (specify location)
If yes, specify area/location

Are there sampling points not fitted with double block or __ No

two valves? __ Yes (specify location)
If yes, specify area/location

How often is safe isolation (e.g. blinds) put in place before __ Always
maintenance works? __ Often
__ Sometimes
__ Rarely
__ Never

What do you do if, in your opinion, there is a more efficient __ I perform isolation as per the plan
method of isolation which is different from the isolation __ I stop the work and inform my supervisor
plan provided to you? __ I use more efficient method of isolation and later inform my
supervisor
__ I use more efficient method of isolation and don’t inform my
supervisor
PSF 5 – Operate override and bypass of safeguards only with authorization

Objective:
 check for inhibition or bypass on the process equipment safeguard systems

To be verified in the field:

 identify all bypassed systems
 check authorizations
 evaluate alternative protection systems
 check the interlocks
 record the bypassed or inhibited elements
 limit bypasses and inhibition over time
PSF 5 – Operate override and bypass of safeguards only with authorization

# Question Answer Notes/Other Considerations

Do you know how to raise an inhibit/override request of a __ Yes

protection system? __ No

Who carries out risk assessment of protection systems __ I don’t know

inhibits/overrides? __ No one
(e.g. Control Room Operator, Production/Shift Supervisor, __ A multi-discipline team (specify)
HSE Representative, etc.) __ Other (specify)

Who formally authorizes every inhibit/override prior to be __ I don’t know

implemented? __ No one
(e.g. Site Manager, Production Superintendent, Production __ Other (specify)
Supervisor, Shift Supervisor, etc.)

Do you record and update every inhibit/override on a __ Usually I don’t record inhibits/overrides
dedicated register? __ I write it in my own note book
__ There is a dedicated log for recording all inhibits/overrides,
visualized in the control room

Usually which is the duration of inhibits/overrides? __ I don’t know

__ a few days
__ more than one week but less than one month
__ more than one month
PSF 6 – Stay within safe operating limits

Objective:
 prevent releases of hazardous fluids or damage to process equipment, resulting from exceeding operating limits

To be verified in the field:

 define operating limits
 ensure the visibility of operating limits
 identify critical parameters
 actively monitor the progress of the parameters
PSF 6 – Stay within safe operating limits

# Question Answer Notes/Other Considerations

Do you know which are the safe operating limits for key __ No
process variables? __ Yes
__ Yes and they are visible to to the operators in the control
room

Do you experience difficulties in establishing the __ Always

criticality/priority of alarms? __ Often
__ Sometimes
__ Rarely
__ Never

Which documents/procedure do you use for taking __ I don’t use documents or procedures
predetermined actions to bring the process variables back __ I have my own reference document, which I created
within the safe limits? __ I use the Operating Manual
__ I use other reference documents (specify)

Can you tell if the Operating Manual is updated and reflects __ The operating manual is regularly updated through the
the current situation of the plant? formal issue of a new revision
__ Any changes to the operating manual are made manually
on the master copy in the control room
__ The operating manual would need updating

When safe operating limits are exceeded, do you report the __ I record the event on a dedicated register and investigate
event and investigate the causes? the causes
__ I record the event but don’t looking for the causes
__ I don’t report the event nor investigate the causes
__ Other (specify)
PSF 7 – Monitor open draining operations

Objective:
 prevent releases during the drainage phases from the equipment into open systems

To be verified in the field:

 identify critical drainage operations
 verify the correct performance of the activity for its entire duration, with particular attention to the alignment of the valves
PSF 7 – Monitor open draining operations
# Question Answer Notes/Other Considerations

Are there lines/equipment which require open drain __ No lines

operations? __ Specify area/location:

How often do you carry out open transfers/ drainages which __ No activities like this
may involve hazardous fluids presence? __ Specify average number per month:

Do you participate in the risk assessment of activities which __ Always Is the evaluation activity tracked? Where can it be
involve open draining or venting into atmosphere? __ Often verified?
__ Sometimes
__ Rarely
__ Never

Can operators leave the draining/transfer location while __ They never leave the location while drainage is in progress
open draining is in progress? __ They leave the location as they have other duties at the
same time
__ They don’t know about the requirement
__ Other reason (specify)

Is it always possible to establish the liquid level in the __ Yes

storage/holding vessels/drums before starting the open __ No (specify location)
draining activity?
If not, specify the area/location.
PSF 8 – Control loading & unloading operations of hazardous fluids

Objective:
 prevent releases during loading and unloading of hazardous fluids

To be verified in the field:

 check the quantity loaded/unloaded
 check the grounding
 check the loaded/unloaded substances to avoid mixing
PSF 8 – Control loading & unloading operations of hazardous fluids

# Question Answer Notes/Other Considerations

How do you ensure that the actual quantity involved in the __ I don’t check
loading operation is in line with the capacity of the receiver? __ I personally verify the exact volume to transfer and the
free volume in the receiving tank/vessel
__ Other (specify)

How do you ensure that the overfill protection is properly __ I don’t check How do you check the accuracy of the instrumentation
working? __ Other (specify) data and possible malfunction of the overfill protection?

How often do you carry out loading operations into __ Always

tanks/vessels that you know do not have overfill protection? __ Often
__ Sometimes
__ Rarely
__ Never

When you use a flexible hose for connection, how do you __ I don’t check
confirm that it was inspected and approved for use? __ There is a label on hose with the inspection date
__ I visually check its condition and the inspection label
__ Other (specify)
PSF 9 – Empty & de-energize process equipment before opening

Objective:
 prevent uncontrolled releases of energy or hazardous fluids during the opening of pipes or equipment

To be verified in the field:

 follow the lock-out/tag-out procedure for the isolation of mechanical and electrical equipment
 record and verify the completion of the isolation plan (P&ID)
PSF 9 – Empty & de-energize process equipment before opening
# Question Answer Notes/Other Considerations

Are there lines where it is not possible to perform complete __ No

isolation of equipment (e.g. leaking/passing valves)? __ Yes (specify location)
If yes, specify the area/location.

How do you check the adequacy of isolations before breaking __ We install a pressure gauge on the line
the first flange joint? __ We break one of the flanged joints to check for residual
pressure
__ Other (specify)

Do you have lines where it is not possible to check the __ No

residual pressure before breaking flange joints? __ Yes (specify location)
If yes, specify the area/location.

Do you use PPE when breaking flange joint after __ Always

depressurization of lines containing hazardous substances? __ Only when there is residual pressure
__ Only if instructed by the supervisor or stated in PTW
__ Never

Do you use the equipment isolation plan to check the __ Always

sequence of isolation (valves and blinds)? __ In most cases
__ Sometimes
__ We don’t use isolation plans at our facility
__ I have never seen the mechanical isolation plan
PSF 10 – Report & manage any loss of containment on site

Objective:
 know and prevent containment losses from the process

To be verified on site:
 report and record any detected or suspected loss
PSF 10 – Report & manage any loss of containment on site

# Question Answer Notes/Other Considerations

If you detect leak, do you report it even if minor (“weeps & __ Always
seeps”) on INDACO as PSE Tier 3.1? __ Often
__ Sometimes
__ Rarely
__ Never

How many leaks from process equipment have you detected __ Specify the average number per year:
during last year, in your working area?

When a loss of containment occurs in your working area, do __ Always

you participate in the investigation to find the causes? __ Often
__ Sometimes
__ Rarely
__ Never

When a loss of containment occurs in your working area, do __ Always

you participate in the preparation of lessons learned? __ Often
__ Sometimes
__ Rarely
__ Never