(Annexure-1) (Rev.8 Date.10.08.

13)

PRE-STARTUP SAFETY REVIEW (PSSR) CHECKLIST FOR RETURN TO NORMAL OPERATIONS AFTER MAJOR SHUTDOWNS

(Ref-Guideline for performing effective Pre-Startup Safety Review-CCPS)

Facility: ___ ________________ _________ Department & Section _________________

Date of PSSR: _______________ _ PSSR Leader: ________________

QUESTION/CONCERN YES/NO/ Ref.Documents Responsibility

NA / Comments (Signature)
A. Pre shutdown activity
A1. Prepare the list of Auditors (Leaders & members) in the format (Annexure-2) for carrying out PSSR
audit for each area and communicate to all concerned.
A2. Quality of Spares- Check quality of all the spares to be used during shutdown to make sure that
these spares are of right specification/quality and procured from approved vendors. (For example QA
documents/critical dimensions for gearbox, motor, coupling, fasteners, temp gauge, pressure gauges
etc.)
A3. Rescue apparatus –Checked different rescue arrangement equipments and made sure that-
(a) Gas Mask is available in ready to use condition
(b) Oxypack is available in ready to use condition
(c) Stretcher is available nearby
A4. Fire protection system
(a)Fire extinguishers are in designated locations.
(b) Fire hydrant system is functional and water pressure is as per system design.
A5. Checking of Cranes and other material handling equipment has been done
A6. Work permit has been taken and as per applicable procedure
A7. Positive Isolation has been done as per procedure
A8. Six Directional Hazard identification has been done and communicated to working agencies
A9. Space allocation for contractors for taking food/rest

B. Activities to be done during Major Shutdown

B1. Walkway should be clear from Slip, Trip and fall hazard
B2. Place has been identified for keeping spares
B3.There is no unbarricated opening in the floor which may cause trip/fall hazard
during shutdown
B4. Quality of Installation-Check all the relevant protocol documents to make sure that all the spares
like motor, gearbox, cable, pulley, fan etc. has been installed as per applicable standard. For example-

1.Insulation resistance test of motors before & after cable connection

2.IR test of cables before & after cable connection

3.Condition of earthing connection of motor & MCC
4.Status of anti-condensation heater (IR & ohmic value of heater & IR of temperature detector)
5.Electrical operation test (Close & trip) for switch gears
6.Mechanical operation test for switch gears
7. Protection relay calibration and testing. (once in 2 years)
8.Auxiliary contact conductance test for switch gears
9.Contact impression for switch gears
10. Complete circuit breaker operation test.
11.Grounding of PLC enclosure
12.Cooling system for PLC
13.Checking of Control program
14. Alignment of Breakers
15. Leveling, alignment, vibration of drives like motor, gearbox, pulley, pump and fans etc.(within
acceptable limit)
16.DP/Radiographic/UT of weld repairs ( if applicable)
17. Installation of applicable safety devices like fusible plugs, torque limiter, flow switches, pressure
switches, zero speed switches etc.
18. Document for leak / pressure test
19. Document for calibration of equipments and systems

C. Activities to be checked towards end of Major Shutdown

C1. Plant inspection done and made sure that –
(a) All the used spares/ assembly/sub assembly and other unwanted materials have been removed
from work site and they are not causing any hindrance/obstruction/ unsafe condition in normal plant
operation.
(b) There is no opening in floor which may cause trip/fall hazard during plant operation or plant inspection.
(c) There is no loose material, grease, lubricant and any other substances lying on pathways, which may
cause slip/trip or fall during plant operation or plant inspection. If spilled lubricant /grease etc. cannot be
removed immediately, it should be cordoned off and communicated to all concerned.
(d) There is no temporary/ permanent cable lying on floor or on pathway, which may cause trip or fall
during plant operation/ plant inspection.
(e) Checked different sections of plant and made sure that all the lights in the work area are adequate and
are operational.
(f) All the temporary structures/ scaffoldings erected during shutdown have been removed and there is no
structure/ scaffolding left in any area, which may create hindrance/ obstruction in safe operation of the
plant.
(g) All the guards are installed for safe operations and maintenance and there is no any equipment which
has remained unguarded, which may pose any risk/danger in safe plant operation.
(h) All the handrails, cages etc. removed during shutdown have been fixed.
(i) If scaffolding is needs to be kept for inspection after plant startup, please specify its removal plan.
C2. Fire protection system- Checked different sections of plant and made sure that-
(a)All the fire detection system like alarms and their sensors are functional.
(b)Fire extinguishers are in designated locations.
(c) Fire hydrant system is functional and water pressure is as per system design. Also, all the above has
been verified by Fire Brigade.
C3. Positive Isolation -
(a) All the locks used for positive isolation have been removed as per procedure and plant is ready to
energize
(b) Number of new equipment installed where provision of positive isolation is to be made-
(c) Number of equipment where provision for positive isolation actually made -
C4. Plant inspection done and made sure that all the warning signs and nomenclature of
new items has been done.
C5. Condition of safety showers and/or eyewashes-
(a) Number of safety showers and/or eye washers in section-
(b) Number of OK safety showers and/ or eye washers -

* C6. Alarms and Interlocks (Software and Hardware)-

All critical alarms, interlocks and signals are restored in original condition (Annexure-3)
C7.Checked the condition of U Seals, water and condensate drain valves, drip pots,
condition of gas line and made sure that-
(a) Condition of gas line, U seal and drip pot, water filling and drain line is healthy (corrosion and leak free).
(This checking is for the gas line network, which is being maintained by department)
(b) Condition of valves for U seal, drip pot, water and condensate drain is ok and they are operational.
(c) U seal and drip pot drain valve in the gas line network has been closed and positive isolation of these
has been done.
(d) All Gas detection systems are operational.

D. Plant inspection done and made sure that before startup/equipment trial, nobody is
there in and around the installation/facility.
Items to be completed after Startup (Applicable if there is any new learning or finding with respect to Safety)
1. Maintenance procedures, ESI document have been updated/ written and all maintenance personnel
trained.
2. Emergency Response plan has been updated/ written and all emergency personnel trained.
3. New equipment added to/revised in maintenance program
4. Drawings and safe operating limits, have been updated, documented, and reviewed with personnel and
distributed to the appropriate locations.
5. Standard operating procedures have been updated or written and all operating personnel trained.
6. All computer control logic has been documented and tested
7. All environmental and industrial hygiene issues have been addressed and documented appropriately.
8. Any necessary PPE changes have been implemented.
9. Any new chemicals have been approved, added to inventory, MSDS available and appropriate training
provided.
10. All modifications effecting permit-required confined spaces have been documented and corresponding
training provided.

The PSSR team concludes that the system/equipment / installation is consistent with specifications and safety requirements
as per the enclosed check list and that the equipment is safe to energize after completion of punch list items mentioned
below, before start-up.

Signature of PSSR Team Leader: Date

Name & Signature of PSSR Team Members:

Approval of start up

(Signature of Chief)
*Departments to prepare a list of critical alarms and interlocks (if not available) before the shutdown.
ITEMS TO BE COMPLETED BEFORE ENERGIZATION / STARTUP

Sl.N
o Description Responsibility Target Date Status

ITEMS TO BE COMPLETED AFTER ENERGIZATION / STARTUP

Sl
No Description Responsibility Target Date Status
Annexure 2

Area Team Leader Team Member Agency (Opn/Mech/IEM/safety)