Annexure-1

(to be filled up by PSSR Team)

PRE-STARTUP SAFETY REVIEW CHECKLIST (Rev.1)
PSSR Items Applicable Action Items Assigned Due
YES/NO description(s) to date
and WHY?

A. General Safety

A.1 Is training on operating procedure provided

to operation & maintenance personnel & the
training document compiled?

A.2 Does all energy isolation points as

mentioned in the document being marked
/labeled physically in the field instruments,
equipment’s, piping’s etc.

A.3 Have bump/trip hazards been properly

identified and marked?

A.4 Have all hot/cold surfaces been identified &

guarded to prevent burns?

A.5 Is measurement of light intensity of 10 lux

for walkways and 65 lux for all corners of
the shop floor, above 1m from the floor,
done & documented

A.6 Is rescue apparatus like Gas mask, Oxy

pack, Stretcher, etc. available in the control
rooms

A.7 Does Gas detection system of all gas prone

areas with its Audio / Video Display
provided in the control rooms.

A.8 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?

A.9 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
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 properly secured?

A.10 Are all of the applicable Work Permit

Procedures (Confined Space Entry, Lock
Out/Tag Out, Hot Work, High Work, etc.) in
place & Operating, Maintenance and
Supervisory personnel been properly
trained?

A.11 Are Safety Showers and Eye Wash facilities

provided?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

B. Machinery Safety

B.1 Has all access to dangerous moving parts, or

danger zones created by the equipment,
been prevented by the provision of the
correct guards, interlocks and/or barriers?

B.2 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?

B.3 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?

B.4 Is the equipment provided with a clearly

identified means to securely isolate it from
ALL energy sources?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date

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 and WHY?

C. Management of Change

C.1 Has a management of change –

technology/subtle change document (for
example, Change of Design - COD) been
approved?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

D. Quality Assurance

D.1 Is there any list of Critical to process

equipment/ component and have checks and
inspections been made to ensure that critical
equipment/components are installed
properly and are consistent with design
specifications and vendor’s
recommendations (for example, alarm and
interlock tests; equipment alignment and
service to process inter-connections)?

D.2 Have quality assurance inspection reports,

covering fabrication, assembly and
installation, been completed in accordance
with the project’s quality assurance plan and
reports filed with the equipment design
basis documentation?

D.3 The construction meets the design

specifications and drawings.

D.4 Have the following documents been

provided and approved:

D.4a Instrument indexes and instrument loop

diagrams?

D.4b A tabulation, including settings, of

interlocks and trips (hardwire and software),
process alarms and permissive descriptions?

D.4c As-built drawings covering P&ID’s, SLD,

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 electrical, piping and mechanical?

D.4d Data sheets for pressure equipment built to

ASME or equivalent codes?

D.4e Non-destructive test (NDT) certifications?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

E. SOP

E.1 Have standard operating procedures been

prepared/updated and approved by
Chief/Head?

E.2 Do the operating procedures cover:

E.2a Initial start-up?

E.2b Normal start-up?

E.2c Normal operations?

E.2d Normal shutdowns?

E.2e Emergency operations including emergency

shutdowns?

E.2f Start-up after emergency shutdowns?

E.2g Start-up following turnarounds/prolonged

shutdowns?

E.2h Non-routine procedure such as equipment

clean-outs and preparation of equipment for
maintenance?

E.2i Auxiliary equipment operations

E.2j Safety and operational issues?

E.2k Change control procedures?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date

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 and WHY?

F. Environment

F.1 Are all secondary containment/bonding

facilities provided?

F.2 Are all material storage facilities adequate

and appropriately labeled?

F.3 Have adequate arrangements been made,

prior to start-up, for the identification,
classification and safe disposal of all waste
materials?

F.4 Have all materials, used in the system, been

entered on the Area Chemicals Inventory
List (or equivalent)?

F.5 Are updated Area Spill Procedures available

& updated?

F.6 Are material Unloading Facilities adequate

and constructed in accordance with
Corporate Safety, Health and Environmental
Standards?

F.7 Is there adequate containment (110% of

volume) in the unloading areas for bulk
liquid chemicals?

F.8 Have all waste streams been identified,

quantified, analyzed and minimized?

F.9 Are all of the applicable Construction,

Environmental and Operating Permits up to-
date and approved?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

G. Electrical Safety

G.1 Have operations/areas been electrically

classified?

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G.2 Has equipment been designed and
purchased for the conditions under which it
will operate? (eg. hazardous areas)

G.3 Are all live parts enclosed to prevent

access?

G.4 Has the design included adequate room for

ventilation of transformers, motors, and
other similar equipment as per IE Rules?

G.5 Does isolation labeling comply with Tata

steel safety standards?

G.6 Are the drawings and PPE‘s (like cool

coats) available as appropriate?

G.7 Have all new Substation Breakers, MCC

isolators, starters or other appropriate
equipment been registered on to the site
inspection schedule?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

H. Fire Protection

H.1 Have the Fire Protection and Prevention

system been designed as per Tata Steel
Standard and have the drawings been
approved by Head, Fire Brigade or his
representative?

H.2 Does the site have a written Fire Protection

Plan that includes a list of the major
workplace fire hazards, proper handling and
storage procedures, potential ignition

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 sources (such as welding, smoking and
others), and the type of fire protection
equipment or systems that can control a fire
involving them?

H.3 Are fire protection facilities provided, e.g.

Fire extinguishers, fire walls, sprinkler
systems, Alarm Boxes, etc., and have they
been included on an inspection Schedule?

H.4 Does the site fire water supply have

sufficient capacity to supply the design
demand for the specified duration (one to
four hours – depending on the severity of
the hazard)?

H.5 Is all portable fire extinguishing equipment

located in proper locations along normal
paths of travel, including exits from areas,
and will this equipment be properly
maintained per NFPA 10.

H.6 Are the persons trained on the use of these

fires fighting equipment?

H.7 Safe access to the firefighting equipment

(like fire tenders) is provided and approval
of Head Fire Brigade or his representative
has been taken?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

I. Engineering Design

I.1 Does Narrative of control

philosophy/Sequence of operations
documentation prepared

I.2 Instrument index prepared & documented

I.3 Instrument loop diagrams verified &

documented

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I.4 Interlock descriptions properly mention or
manual documented

I.5 Compilation of As-built drawings: P&ID’s,

electrical, piping, mechanical done &
verified by Engineering.

I.6 Tabulation sheet prepared of process alarms,

interlocks/permissive descriptions and trips
with settings (P&IDS)

I.7 Piping specifications (P&IDS/mechanical

drawings) mentioned

I.8 Design codes for specific equipment

mentioned & documented

I.9 Electrical classification drawings

documented

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

J. Industrial Hygiene &Personnel Health

J.1 Have all health risks due to gases, liquids,

dusts, Heat stress /exposure, mists , Noise
or vapors used by, contained in or emitted
by this equipment been assessed, and where
necessary, eliminated or controlled?

J.2 Has adequate Personal Protective

Equipment (PPE) and/or Respiratory
Protective Equipment (RPE) been specified
in the Operating Procedures?

J.3 Are up to date material safety data sheets

(MSDS) available and displayed?

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J.4 Have Operating Procedures been reviewed
to take into account any additional “hazards
to health” which may arise from operation
or maintenance of this equipment?

J.5 Are relief facilities directed to a safe place

away from the workplace?

J.6 Has a Noise Survey been considered and a

Noise Compliance Plan prepared, if
required?

J.7 Has Periodical Medical Examination in

view of exposure to hazardous work
assessed and listed.

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

K. Ergonomics

K.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?

K.2 Labeling of equipment, piping, critical

valves, field instruments, switches clear?

K.3 Sampling points accessible?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

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L. Mechanical Integrity

L.1 Have maintenance procedures been

approved by Head of Maintenance?

L.2 Have maintenance personnel been trained?

L.3 Have quality control procedures been

approved for maintenance materials and
spare parts?

L.4 Have inspections and tests, (including

regulatory requirements) for the following
equipment been included in a maintenance
schedule?

L.4a Pressure vessels and storage tanks?

L.4b Pressure relief systems, vent systems and

devices?

L.4c Critical controls, interlocks, alarms and

instruments?

L.4d Emergency devices (including shutdown

systems and isolation systems)?

L.4e Piping systems (incl. Components, for

example, valves, excess flow valves,
expansion bellows) in critical service?

L.4f Electrical earthing, grounding?

L.4g Emergency alarm and communication

system?

L.4h Monitoring devices and sensors?

L.4i Have all commissioning tests or inspections

been identified (for example, pressure or
leak tests, passivation procedures)?

L.4j Lifting equipment?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

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M. Contractor Safety

M.1 Have all contract personnel been adequately

trained in appropriate: chemical awareness,
maintenance and operating activities and
evacuation procedures?

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PSSR Items Applicable Action Items Assigned Due
YES/NO description(s) to date
and WHY?

N. Road Safety

N.1 Have the planning of roads inside plant and

their access to main road been approved by
Safety?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

O. General Process Safety

O.1 Process Safety Information updated?

O.2 Process Hazard Analysis (PHA) report(s)

complete?

O.3 All PHA action items completed?

PSSR Items Applicable Action Items Assigned Due

YES/NO description(s) to date
and WHY?

P. Community Awareness & Emergency Response

P.1 Have all necessary precautions been taken

to ensure that the equipment is not a source
of ignition to any flammable materials,
irrespective of their source?

P.2 Are Emergency Escape Routes, including

ladders, properly signposted?

P.3 Is Emergency Lighting provided?

P.4 Have Emergency Procedures been prepared

and relevant personnel trained?

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