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Pre-Startup Safety Review Checklist New Plant



1. Conducted HAZOP or similar safety study for the

2. Road or passage to the operating area (including
offices) to be made safe for inward movement of men
machinery and emergency vehicles and simultaneously
safe evacuation route from the operating areas. Provide
suitably identified emergency exits prominently marked
EMERGENCY EXIT in green fluorescent paint or
boards or marking on all levels (floors). Special
considerations to be given to closed rooms. The rooms /
passages leading to a dead end must be marked in red
with NO EXIT. The emergency exit door should not
open to outside directly on steps. The emergency exit
should not have provision of locking from either side.
3. Adequate day time and night time lighting in all areas of
the plant as per standards. Light fittings should comply to
the requirements of the areas (viz. Flameproof / non
flameproof). The light fittings should be fitted in such a
way that the repair or maintenance is done safely.
7. Adequate working space (min 1 meter) around reactors
should be available for safe operation. Due consideration
is to be taken for space if material movement is required
in drums, and other containers & trollies.
8. Emergency lights in all operating areas including closed
rooms and stair cases.
9. Fire alarm and suitable fire control measures (fire
extinguishers/automatic CO2 flooding system/fire hose
reels/fire hydrant system) on each floor. Thermal sensor
alarms to be provided, for areas not visited after general
shift hours. Please refer National Building Codes of India
2005, Part 4 for Fire & Life Safety
10. All hazardous locations or area should be provided
with fire hydrant system with proper loops with minimum
two hydrant points at opposite sides.. Also standby diesel
driven hydrant pump of equal rating should be provided.
11. All electrical equipment / plant equipment and
machinery must be provided with double earthing.
12. All tanks / vessels having flammable solvents must be
provided with Separate earth pits for equipment, neutral
of electrical & for lightning arrestors.
13. Provision of interlocked safety barriers (bars/cages)for
equipments like rotocone dryer, blender etc.
14. Provision of LOTO system for all MCCs, equipment,

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must be provided.
15. Guards of adequate design (based on point of
operation) and strength must be provided to every
moving part (couplings, belt drive, motor fans etc).
16. Proper and adequate storage space for storage and
handling of hazardous chemicals must be provided.
Separate space for storage of gas cylinders (which come
under Unfired Static Pressure Vessels as per Petroleum
Explosive Safety Organization (PESO) must be provided.
17. Provide adequate space for storage of PPE in the
operation area for employees of the area along with
change room and toilet for facilities. Separate & adequate
toilet & rest room facilities to be provided for ladies,
where applicable.
18. Adequate numbers of eye-bath / Safety shower with
water supply
19. Ensure separate enclosures are provided for tanks
storing hazardous solvents with dyke wall (including dyke
valve) as approved by PESO.
20. Ensure adequate enclosed space is provided for
storage of solvent in drums, fitted with exhaust fans and
sumps min. 250 lts. holding capacity. The floor should
direct the spillage / leakage, if any, towards the sump.
21. Adequate day time and night time lighting in all areas
of the plant
22. Nitrogen blanketing in all centrifuges with a Rota
meter to check the flow of gas.
30. For explosion release (especially in FBD) the explosion
vent should open outside in a safe area (with no or least
manpower movement). Such areas should not have NFLP
31. The vents of the reactors should also be fitted with
flame arrestors and the vent should be above 3 mtr. of the
32. Entry and exit access to the plants must be clear of any
33. Line and equipments should be installed, as far as
possible, in such a way that they do not become head
knockers or trip hazard.
34. Illumination in the workplace should be maintained as
per the requirement (min. 30 Lux at floor level- in
35. All staircases shall be provided with railing on both
sides. Railing heigh shall be min. 42 inch, with mid rail and
toe board at the bottom.

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36. All platforms where there is a potential for falling must

be provided with safety railings.

[B] Environment
1. Dust collector and exhaust hood at the point of solid
charging in the reactors must be provided. Dust collection
system to be connected to the scrubber system with
secondary containment around scrubbers.
2. Scrubber must be provided for scrubbing fugitive
emission of solvents from processes equipment such as
reactors, tanks, vessels, centrifuges, dryers etc. Scrubbers
to be connected to emergency power supply- so that in
case power is stopped to the individual plant the
scrubbers connected to this remains working.
9. Keep provision for greenery (Plantation) as per
guidelines of local Pollution Control Board/ Central
Pollution Control Board.
10. Provide a large underground reservoir (approx.
capacity 300M3) to store used fire water before pumping
it to ETP for treatment.
11. ETP of adequate capacity must be planned with a
provision to recycle the treated water for non process
use. Dust collector and exhaust hood at the point of solid
charging in the reactors
12. Tank Farm area (including day tank area) must be
provided with dikes (bunds) for containing the spillages,
with provision for collection and transfer arrangement.

[C] Solvent Handling

1. Day storage tanks for solvents provided
2. Closed transfer system for transferring solvents from
day tanks to charge vessels. Earthing & Bonding (jumpers)
on flammable solvent transfer lines.
3. Charge vessels for charging solvents in reactors
All motors in flammable solvent handling/storages
area shall be flameproof/weatherproof type.
All bulk storage tanks in the process area should
have dykes around them.
The area must have two earth pits for grounding
purposes with interconnections.

[D] Compressed Gas Cylinder Handling

1. Compressed gas cylinders are to be stationed outside
the rooms, buildings, at ground floor and necessary tubing
are given to the required level/floor.
2. The connector pipes and its contents are compatible
with cylinder pressure and contents.
3. Regulators (& safety relief valve- wherever applicable)
must be provided to all cylinders' headers.

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6. Required fall arrest system shall be provided to all

points of cylinder use.

[E] Buildings:
1. The building shall be earthquake resistant.
2.The floor to floor height shall be as per National Building
Code of India (issued by BIS).
7.The buildings shall have sufficient nos. of emergency
exits as per Factories act 1948 Rule 66 A(9) / OSHA CFR
1910. 36. All emergency exits doors shall open outside and
shall be maintained as per CFR 1910.37
8.The building shall have sufficient nos. of First aid fire
extinguishers fitted at appropriate locations.
9.The building shall have pressurized fresh air supply
connections for use with fresh air/ breathing air
hoods/masks (full face/half face). The air quality shall meet
recommendations of OSHA (as appended)
10.The building shall have provisions for flameproof
telephones (in areas where hazardous flammable area is
or likely to be present).
11. All floors where there is potential of falling, from higher
to lower levels, should have required fall protection
(parapet wall railing) measures.

1. Have training been provided for operation &
maintenance of the process / machinery / equipment
2. Is training provided to handle emergencies as envisaged
in project/ process/
3. Has competency been assessed before putting the
person on the job.

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