化工廠常用PSSR檢查表.doc

1、PSSR Checklist Example A-1PSSR清單示例 A-1Description ofSystem/Area Under ReviewDateTime所審查系統(tǒng)/區(qū)域的描述日期時(shí)間List of ParticipantsCirculation: those present plus參與者名單傳閱：參加人員加上Comments討論ItemRecommendationNo.(Type Action Below or notapplicable)序號建議（請?zhí)顚懴铝行袆禹?xiàng)或注明“不適用”）1. Review HAZOP list for applicableactions查看 HA

2、ZOP 列表看相關(guān)行動項(xiàng)是否解決2. Review CHAZOP list for applicable actions查看 CHAZOP列表看相關(guān)行動項(xiàng)是否解決3. Reviewpunch list rfoapplicable actions.查看剩余工作清單看相關(guān)行動項(xiàng)是否解決4. Noiselevel monitoring (document)噪音等級監(jiān)測（文件）5. Exposure monitoring (document)操作人員暴露風(fēng)險(xiǎn)監(jiān)測（文件）6. Emissions permits排放許可7. Other operating permits其他允許的行動System Che

3、ckout Items系統(tǒng)檢查項(xiàng)目8. Complete/document qualityassurance program:完成質(zhì)量保證體系并建立了文檔a) Received equipment=purchased收到的設(shè)備=購買的設(shè)備b) Adherence todesign drawings/specifications采用的設(shè)計(jì)規(guī)范c) Materials of construction施工材料d) Workmanship工藝技術(shù)Department /CompletedResponsibleDatePerson完成日期部門/責(zé)任人1/36ItemRecommendationNo.(T

4、ype Action Below or notapplicable)序號建議（請?zhí)顚懴铝行袆禹?xiàng)或注明“不適用”）.Equipment components checkout/commissioning (document)設(shè)備部件檢查/調(diào)試（文件）9. Loop and interlock/permissive/alarm: set point adjustment and testing (document esults)r回路和聯(lián)鎖/許可/報(bào)警：設(shè)置點(diǎn)調(diào)整和測試（文檔記錄）10. Instrument calibrations done and documented儀表校訂完成并記錄11.

5、 Validation protocol developed, approved andexecuted制定、批準(zhǔn)和執(zhí)行的驗(yàn)證協(xié)議12. Pressure testing done and documented壓力測試完成并記錄13. System cleaned and flushed系統(tǒng)已完成清掃、沖洗14. Fireprotections systems inspected, acceptance-tested documentation provided消防系統(tǒng)已檢查，并有測試、驗(yàn)收記錄15. Ventilationsystems balanced通風(fēng)系統(tǒng)已平衡16. Performa

6、ncecheckout of local exhaust systems局部排氣系統(tǒng)的性能檢測17. Vibration measurements/documentation振動測量記錄18. Field radiography done and documented as equiredr現(xiàn)場放射性物質(zhì)檢測已完成并記錄19. Baseline data, such as thickness eadingsr forpressure vessels/piping基礎(chǔ)數(shù)據(jù)，如壓力容器/管線的壁厚20. Other baselinedata其他基礎(chǔ)數(shù)據(jù)21. NDT reports無損檢測報(bào)告22

7、. Water batching (document)配水（記錄）Engineering Design Documentation工程設(shè)計(jì)資料23. Narrative of control philosophy/Sequence of operations documentation操作控制原理/操作順序的說明資料24. Instrument index儀表索引25. Instrument loop diagrams儀表回路圖26. Interlock safety( & non-safety) descriptions聯(lián)鎖（安全和非安全）描述Department /CompletedRes

8、ponsibleDatePerson完成日期部門/責(zé)任人2/36ItemRecommendationNo.(Type Action Below or notapplicable)序號建議（請?zhí)顚懴铝行袆禹?xiàng)或注明“不適用”）27. As-built rawings:d P&IDs, electrical, iping, mechanical竣工圖：PID圖，電氣圖，配管圖，機(jī)械圖28. Tabulation of process larms, interlocks/permissive descriptions and trips with settings P&ID)(工藝報(bào)警表、聯(lián)鎖/許可說

9、明表和帶設(shè)定值(P&ID)的跳轉(zhuǎn)表29. Reviewand approval of fire protections systems design消防系統(tǒng)設(shè)計(jì)的審查和許可30. Pipingspecifiations P&I/mechanical( drawings)配管圖（PI圖 /機(jī)械圖）31. Pressure relief devicesizing calculations安全閥規(guī)格的選定計(jì)算32. ASME code pressure vessels U-1 data sheets to( Maintenance)壓力容器 ASME 代碼 U-1 數(shù)據(jù)表（用于維修）33. Refe

10、rence codes/standards for facilitydesign裝置設(shè)計(jì)的參考規(guī)范/標(biāo)準(zhǔn)34. Reference codes/standards for facilityinstallation設(shè)備安裝的參考規(guī)范/標(biāo)準(zhǔn)35. Design codes for specifi equipment特殊設(shè)備的設(shè)計(jì)規(guī)范36. Welder certification焊工資格證書37. NDT certification無損檢測證書38. Electrical classification drawings電器分類圖39. Electrician certification for c

11、lassified areas特定施工區(qū)域的電工資格證書Maintenance Items維修項(xiàng)目40. Spare parts stsli developed List equipment:備品備件清單并附設(shè)備清單41. Stock equiredr spare parts備品備件所需儲存設(shè)施42. Equipment manuals/specificationsto Maintenance and OperatingDepartment維修和操作部門的設(shè)備手冊/說明43. Vendor prints供應(yīng)商提供的印刷資料44. Submit preventive maintenance re

12、quests PM(s)提交的預(yù)防性維修要求45. Servicecontracts inplace服務(wù)合同已簽訂Department /CompletedResponsibleDatePerson完成日期部門/責(zé)任人3/36ItemRecommendationNo.(Type Action Below or notapplicable)序號建議（請?zhí)顚懴铝行袆禹?xiàng)或注明“不適用”）46. Trainmaintenance personnel and document培訓(xùn)維修人員和相關(guān)培訓(xùn)資料Operational Items生產(chǎn)項(xiàng)目47. Develop SOP and special pro

13、cedures incorporate safetyand operational issues:編寫標(biāo)準(zhǔn)操作規(guī)程（SOP）及特殊操作規(guī)程考慮了操作風(fēng)險(xiǎn)和可操作性問題48. Complete change control authorizations完成變更控制授權(quán)49. Develop/issue operating procedures:制定/頒布下列操作規(guī)程a) Initial star -up初次開車b) Normal start-up正常開車c) Normal operation正常操作d) Normal shutdown正常停車e) Emergency operations inc

14、luding emergency shutdown包括緊急停車的應(yīng)急操作f) Start-up following emergency shutdown緊急停車后開車g) Start-up following turnaround大修后開車h) Non-routineprocedures (equipment clean-out, equipment preparationformaintenance)非常規(guī)程序（設(shè)備清理、設(shè)備維修準(zhǔn)備）i) Auxiliary equipment operation輔助設(shè)備的操作50. Train operatingpersonnel and documen

15、t培訓(xùn)操作人員和相關(guān)培訓(xùn)資料51. Providetechnical coverage技術(shù)服務(wù)范圍52. What isthe probabilityof containment failure? What are the subsequent consequences? Review spill containment, rainwater runoff, and fire water containment.防泄漏設(shè)施的失效概率是多少？失效的后果是什么？審查防泄漏設(shè)施、雨水流量和消防水容量Electrical Issues電氣問題53. Panel access, clearance ar

16、ound panel, keys,etc.配電盤的通道、配電盤周圍的間隙、鑰匙等Department /CompletedResponsibleDatePerson完成日期部門/責(zé)任人4/36ItemRecommendationNo.(Type Action Below or notapplicable)序號建議（請?zhí)顚懴铝行袆禹?xiàng)或注明“不適用”）54. Cable entry section glanding, housekeeping and other issues電纜接入部分密封、保潔及其他問題55. Panel power source identified? Multiple fe

17、eds?配電盤電源的標(biāo)識？多源供電？56. Spaceheaters required?需要空間加熱器嗎？57. Lighting inpanels配電盤里的照明58. Canopies etc. for outdoor panels用于室外配電盤的雨棚等59. Protection settings available?有保護(hù)設(shè)置嗎？60. Panel board schedules配電盤面板清單61. Spare capacityavailable?有備用容量嗎？62. PPE available? HV mats,gloves有個(gè)人防護(hù)用品嗎？有高壓絕緣墊嗎?有高壓絕緣手套嗎?63. E

18、mergency/Standby power required?有應(yīng)急/備用電源嗎？64. VSD settings availablefactory/commissioning變頻器設(shè)置工廠/調(diào)試65. Room access, permitting, maintainability, ingress/egress of equipment房間通道、許可證、可維修性、設(shè)備的進(jìn)出通道66. Pockets for drawings inpanels?配電盤的圖紙集67. Voltage warning labels?電壓警告標(biāo)簽68. Ventilationsufficient?通風(fēng)充足嗎？6

19、9. Suitabilityfor area - IP ating,r GMP suitability, hazardous area classification.區(qū)域適宜性國際防護(hù)等級、GMP 適宜性、危險(xiǎn)區(qū)域分類- Relief Devices- 泄放設(shè)備70. Are there standard markings on the P&ID?在 P&ID圖上有標(biāo)準(zhǔn)代號嗎？71. Do relief lines vent toa safe location?放空線排放到一個(gè)安全地點(diǎn)嗎？72. Are relief lines and relief devices secured and a

20、dequately sized?放空線和泄放設(shè)備安全嗎?尺寸足夠大嗎？Department /CompletedResponsibleDatePerson完成日期部門/責(zé)任人5/36ItemRecommendationNo.(Type Action Below or notapplicable)序號建議（請?zhí)顚懴铝行袆禹?xiàng)或注明“不適用”）73. Are there any isolation valves whichwill inhibit operationof relief valves if closed? If YES, nominate Operations to monitor.

21、IfNO, record no.有處于關(guān)閉狀態(tài)會抑制放空閥操作的隔離閥嗎？如果有，請指定操作人員對其進(jìn)行監(jiān)視。如果沒有，記錄無74. Is there a standard operatingprocedure forrelief devices in place?現(xiàn)場有泄放設(shè)備的標(biāo)準(zhǔn)操作規(guī)程嗎？- For Field Verification- 現(xiàn)場確認(rèn)75. Is lighting sufficient?照明充足嗎？76. Is emergency lighting sufficient?應(yīng)急照明充足嗎？77. Are steam pipes, valves, or traps situa

22、ted within proximity of peopleinsulated?位于人接近范圍內(nèi)的蒸汽管線、閥門或疏水器被隔離了嗎？78. Is all instrumentation identified and tagged?所有的儀表都有標(biāo)識和掛牌了嗎？79. Is there any rusted ordamaged equipment?有任何生銹或損壞的設(shè)備嗎？80. Are swing gates installed on top of ladders or on access platforms?在梯子頂部或平臺通道上安裝了止回門嗎？81. Reviewedgeprotectio

23、n on platforms and heights.Will it protect personnel and equipment? Isaccess adequate?檢查平臺和高處的邊緣保護(hù)。它能保護(hù)人員和設(shè)備嗎？通道足夠嗎？82. Do safety showers provide a hazard topeople (slips), product contamination( of systems), or ingressto electrical switchgear or equipment?安全噴淋對人(滑跤的危險(xiǎn))、產(chǎn)品（系統(tǒng)的污染）或內(nèi)部的電氣開關(guān)柜或設(shè)備產(chǎn)生危險(xiǎn)了嗎？8

24、3. Are safetyshowers suppliedfrom tempered water?安全淋浴供應(yīng)熱水嗎？84. Is chemical dosing withina safe proximityof people and product?化學(xué)品操作是在人和產(chǎn)品安全接近范圍內(nèi)嗎？85. Label all ipe lines標(biāo)識所有的管線86. Label all lectricswitches, disconnects,MCCs, control panels, cables, etc.標(biāo)記所有的電氣開關(guān)、中斷器、電動機(jī)控制器、控制盤和電纜87. Label vessels (m

25、aterial, hazard warnings) List:標(biāo)記容器（材料、危險(xiǎn)警告）的清單Department /CompletedResponsibleDatePerson完成日期部門/責(zé)任人6/36ItemRecommendationNo.(Type Action Below or notapplicable)序號建議（請?zhí)顚懴铝行袆禹?xiàng)或注明“不適用”）88. Seal wall penetrations密封墻壁的滲透89. Pour conduit seals灌注導(dǎo)管的密封90. Install fire extinguishers91. Evacuation routes post

26、ed92. Install appropriate area signs93. Is all scaffolding and equipment removed; is eneralg housekeepingacceptable?94. If there is potential for entrapment or exposure, has an E-Stop been provided?95. If full guarding is inplace, has a lockable isolation device been provided?96. Pest control equire

27、dr inroom/building?97. MSDS sheets equired?r98. Sprinklers inrooms?99. Singlepoint of failure condition? Has it been identified? Record.Department /CompletedResponsibleDatePerson完成日期部門/責(zé)任人7/36PSSR Checklist Example A-2Prestartup- Safety Review ChecklistInspection Date:Department/Area:Project Number:

28、Title/Equipment:Signatures below indicate acceptance that the equipment or project is safe and satisfactory to start-up withthe exceptions noted.Engineering /MaintenanceDateEHS GroupDateQA GroupDateManufacturing / OperationsDateProject EngineerDateProcess EngineeringDate8/36ChecklistDetails (referen

29、ce category/item no.)ResponsibilityItem No.Category A Action Items -Items tobe completed BEFORE authorizationand star -up1.2.3.4.5.Category B Action Items -Items tobe completed AFTERstart-up1.2.3.4.5.6.7.8.9.10.11.12.Sign below onlywhen allpunch listbefore“ start-up”items are completedAuthorized:Fac

30、ility/Equipment Owner Signature:CompleteSign &DateDate9/36PSSRITEMCATEGORY/ITEM TO ASSESSNotNO.Applicable1.1GENERAL SAFETY1.1.1HaveALL appropriatepersonnel (Operations, Maintenance, Technical, andSupervision) received adequate and appropriate training on the equipment andoperating procedures?1.1.2Ha

31、s adequate and appropriatePPE (Personal Protective Equipment) beenspecified intheWork Procedures and/or Standard OperatingProcedures.Has the PPE been provided?Have thePPE users been trained inthe use of the PPE?Is the training documented?1.1.3Have measures been taken to adequately guard all dangerou

32、s parts of thisequipment?1.1.4Hassufficient provisionbeenmade for the electrical and/or mechanical isolation of theequipment?1.1.5Are points of solationi clearly marked/labeled and readily accessible?1.1.6Have bump/trip hazards been properly identifiedand adequately marked?Have all sharp edges been

33、removed?1.1.7Has proper guarding, handrails/barriers, been provided toprevent falls?1.1.8Have all hot/coldsurfaces been adequately guarded toprevent burns?Are all cold surfaces adequately insulated toprevent condensation drips slip(hazards)?1.1.9Are Safety Showers and EyeWashfacilities provided anda

34、dequatelymarked?Are the Safety Showers and EyeWashfacilities routinely inspected?Do the Safety Showers and EyeWash facilities locations complywithCorporateguidelines?Are the Safety Showers and EyeWashfacilities readilyvisibleand accessible?1.1.10Hassufficient lighting beenprovided so that operation,

35、 servicing, maintenance, andrepair of the facilities can be carriedout safely?1.1.11Are notices, dials, screens, etc.for providing operational instructions,safety warnings,and emergency information provided, if equired,r and positioned so that they areclearly visibleand easilyread?1.1.12Have all ove

36、rhead fixtures, for example, pipe-hangers, pipe sleves, pipe sleevecovers, valve handles, flor opening covers, etc., whichcould fall orbe dislodged,been properly secured?1.1.13Are all of the applicableWork Permit Procedures (Confined Space Entry, LockOut/Tag Out, Hot Work, HighWork, etc.)inplace?Hav

37、e theOperating, Maintenance, and Supervisory personnel been properly trainedon theWork Permit Procedures?1.1.14Has the fire protection systems been inspected by the insurance company?Has acceptance testing been completed and documented?Is there an agreed on test and inspection program for the fire p

38、rotection systems(including alarmsystems)?1.2MACHINERY/EQUIPMENT SAFETY1.2.1Has themachinery/equipment been installedso that it will bestable and secureduringoperation?1.2.2Has all accessto dangerous moving parts, ordanger zones created by theequipment, been prevented by the provision of the correct

39、 guards, interlocks both(safety & non-safety) and/or barriers?1.2.3Have thecorrect safetymeasures been taken toprevent any riskfrom hot/coldsurfaces, jection ofmaterial, failure of parts and their ejection, overheating/fire?10/36PSSRITEMCATEGORY/ITEM TO ASSESSNotNO.Applicable1.2.4Hassafe access been

40、 provided tothe equipment that requires operator andcalibration andmaintenance personnel access for normal operations, adjustments,service, calibration, maintenance, or repair?Have slip, trip, trap, crush, entanglement, fall, ump,band cut hazards beenminmized?1.2.5Is the equipment provided withthe p

41、roperly identifiedSTART/STOP andEMERGENCY controls that are positioned for safe operation without hesitation, orloss of time, and without ambiguity?1.2.6Is the equipment provided witha clearly identifiedmeans tosecurely isolate it fromALL energy sources?1.3ERGONOMICS1.3.1Have theworkstations, workpl

42、ace, or equipment been constructed so that need forstooping, bending stretching, over-reaching and working over-head during operationhas been eliminated or minmized?1.3.2Has the need tolift,carry, push or pull heavy loads, or parts, been eliminated totheextent possible?1.3.3Are all display screens,

43、dials andSTART/STOP/ EMERGENCY buttons positionedso that they are readilyvisible and accessibleby theoperating personnel?1.3.4Have Visual DisplayScreens been positioned so that interference from glare isreduced tothe minmum?1.3.5Have workstations been designed and equipped so that the operator can a

44、dopt acomfortableposition? (That is,able tostand, or change position and sit pright,u angleat elbows and knees 90 , fet on flor.)1.3.6Does the operation of this equipment increasethe risk of Upper Limb Disorder; forexample, repetitivetasks,handling operations,machine paced work and prolongedoperatio

45、n?1.4OCCUPATIONAL HEALTH1.4.1Have all healthrisks arising from the gases, liquids, dusts, mists, biological hazards orvapors used by, containedin or emited by this equipment been assessed?Have thehealthrisks eenb eliminated or are adequate engineering controls utilized tominmize the risks?1.4.2Has a

46、dequateRPE (Respiratory Protective Equipment) been specified in theOperatingProcedures?1.4.3Has the need for an Occupational HealthMonitoring Programmebeen assessed?Has aMonitoring Programme been scheduled?1.4.4Have theOperating Procedures been reviewed totake into account any additional“health haza

47、rds”whichmay arisefrom operationor maintenance of this equipment?1.4.5Has adequateLEV (Local ExhaustVentilation) been installed, tested, balanced, andentered on an Inspection Schedule?1.4.6Have adequate inspection/cleaning ports been provided onductwork?1.4.7Are relief facilities directed toa safe p

48、lace away from the workplace?1.4.8Has aNoiseSurvey been considered and aNoiseCompliance Plan prepared, ifrequired?1.4.9Has all insulation been identified?1.4.10Has all ipe work, tanks, and equipment containing hazardous materials beenadequately labeled?2.0PROCESS SAFETY2.1PROCESS TECHNOLOGY2.1.1Are

49、up-to-date Material SafetyData Sheets available?2.1.2Have thehazardous effects of inadvertent mixing of different materials beenconsidered (tha is,has a chemical interactionmatrix been prepared/updated)?11/36PSSRITEMCATEGORY/ITEM TO ASSESSNotNO.Applicable2.1.3Has the process design basis been docume

50、nted or updated?Has the control philosophy and sequence of operations been documented?2.1.4Has the equipment design basis for( example, BPFs/P&IDs) beendocumented/updated?2.1.5Have therecommendations from safetyreviews, Process Hazards Analysis PHA),(Hazards and OperabilityReviews (HAZOP), CHAZOP, or others, beenimplemented?Record any incomplete items.2.1.6Are all eliefr devices shown on the P&IDs?Are standard markings used on the relief devices?Are the relief/rupture pressures included on the P&IDs?2.1.7Have thepressure relief dev