化工廠常用PSSR檢查表(doc 36頁(yè)).doc

1、PSSR Checklist Example A-1PSSR清單示例A-1Description of System/Area Under Review所審查系統(tǒng)/區(qū)域的描述Date日期Time時(shí)間List of Participants參與者名單Circulation: those present plus傳閱：參加人員加上Comments討論ItemNo.序號(hào)Recommendation(Type Action Below or not applicable)建議（請(qǐng)?zhí)顚?xiě)下列行動(dòng)項(xiàng)或注明“不適用”）Department / ResponsiblePerson部門/責(zé)任人CompletedD

2、ate完成日期1.Review HAZOP list for applicable actions查看HAZOP列表看相關(guān)行動(dòng)項(xiàng)是否解決2.Review CHAZOP list for applicable actions查看CHAZOP列表看相關(guān)行動(dòng)項(xiàng)是否解決3.Review punch list for applicable actions.查看剩余工作清單看相關(guān)行動(dòng)項(xiàng)是否解決4.Noise level monitoring (document)噪音等級(jí)監(jiān)測(cè)（文件）5.Exposure monitoring (document)操作人員暴露風(fēng)險(xiǎn)監(jiān)測(cè)（文件）6.Emissions permi

3、ts排放許可7.Other operating permits其他允許的行動(dòng)System Checkout Items系統(tǒng)檢查項(xiàng)目系統(tǒng)檢查條目8.Complete/document quality assurance 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(gòu)買的設(shè)備b) Adherence to design 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).Equipment components ch

4、eckout/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 results)回路和聯(lián)鎖/許可/報(bào)警：設(shè)置點(diǎn)調(diào)整和測(cè)試（文檔記錄）10.Instrument calibrations done and documented儀表校訂完成并記錄11.Validation protocol developed, approved and executed制定、批準(zhǔn)和執(zhí)行的驗(yàn)證協(xié)議12.Pressure testi

5、ng done and documented壓力測(cè)試完成并記錄13.System cleaned and flushed系統(tǒng)已完成清掃、沖洗14.Fire protections systems inspected, acceptance-tested documentation provided消防系統(tǒng)已檢查，并有測(cè)試、驗(yàn)收記錄15.Ventilation systems balanced通風(fēng)系統(tǒng)已平衡16.Performance checkout of local exhaust systems局部排氣系統(tǒng)的性能檢測(cè)17.Vibration measurements/documentati

6、on振動(dòng)測(cè)量記錄18.Field radiography done and documented as required現(xiàn)場(chǎng)放射性物質(zhì)檢測(cè)已完成并記錄19.Baseline data, such as thickness readings for pressure vessels/piping基礎(chǔ)數(shù)據(jù)，如壓力容器/管線的壁厚20.Other baseline data其他基礎(chǔ)數(shù)據(jù)21.NDT reports無(wú)損檢測(cè)報(bào)告22.Water batching (document)配水（記錄）Engineering Design Documentation工程設(shè)計(jì)資料23.Narrative of c

7、ontrol philosophy/Sequence of operations documentation操作控制原理/操作順序的說(shuō)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27.As-built drawings: P&IDs, electrical, piping, mechanical竣工圖：PID圖，電氣圖，配管圖，機(jī)械圖28.Tabulation of process alarms, inte

8、rlocks/permissive descriptions and trips with settings (P&ID)工藝報(bào)警表、聯(lián)鎖/許可說(shuō)明表和帶設(shè)定值(P&ID)的跳轉(zhuǎn)表29.Review and approval of fire protections systems design消防系統(tǒng)設(shè)計(jì)的審查和許可30.Piping specifications (P&I/mechanical drawings)配管圖（PI圖 /機(jī)械圖）31.Pressure relief device sizing calculations安全閥規(guī)格的選定計(jì)算32.ASME code pressure v

9、essels 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.Reference codes/standards for facility design裝置設(shè)計(jì)的參考規(guī)范/標(biāo)準(zhǔn)34.Reference codes/standards for facility installation設(shè)備安裝的參考規(guī)范/標(biāo)準(zhǔn)35.Design codes for specific equipment特殊設(shè)備的設(shè)計(jì)規(guī)范36.Welder certification焊工資格證書(shū)37.NDT certification無(wú)損檢測(cè)證書(shū)38.Electri

10、cal classification drawings電器分類圖39.Electrician certification for classified areas特定施工區(qū)域的電工資格證書(shū)Maintenance Items維修項(xiàng)目40.Spare parts lists developedList equipment:備品備件清單并附設(shè)備清單41.Stock required spare parts備品備件所需儲(chǔ)存設(shè)施42.Equipment manuals/specifications to Maintenance and Operating Department維修和操作部門的設(shè)備手冊(cè)/說(shuō)

11、明43.Vendor prints供應(yīng)商提供的印刷資料44.Submit preventive maintenance requests (PMs)提交的預(yù)防性維修要求45.Service contracts in place服務(wù)合同已簽訂46.Train maintenance 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 procedures incorporate safety and operational issues:編寫(xiě)標(biāo)準(zhǔn)操作規(guī)程（SOP）及特殊操作規(guī)程考慮了

12、操作風(fēng)險(xiǎn)和可操作性問(wèn)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 start-up初次開(kāi)車b) Normal start-up正常開(kāi)車c) Normal operation正常操作d) Normal shutdown正常停車e) Emergency operations including emergency shutdown包括緊急停車的應(yīng)急操作f) Start-up following emergency shutdo

13、wn緊急停車后開(kāi)車g) Start-up following turnaround大修后開(kāi)車h) Non-routine procedures (equipment clean-out, equipment preparation for maintenance)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 operating personnel and document培訓(xùn)操作人員和相關(guān)培訓(xùn)資料51.Provide technical coverage技術(shù)服務(wù)范圍52.What is the probabi

14、lity of 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(wèn)題53.Panel access, clearance around panel, keys, etc.配電盤(pán)的通道、配電盤(pán)周圍的間隙、鑰匙等54.Cable entry section glandin

15、g, housekeeping and other issues電纜接入部分密封、保潔及其他問(wèn)題55.Panel power source identified? Multiple feeds? 配電盤(pán)電源的標(biāo)識(shí)？多源供電？56.Space heaters required?需要空間加熱器嗎？57.Lighting in panels配電盤(pán)里的照明58.Canopies etc. for outdoor panels用于室外配電盤(pán)的雨棚等59.Protection settings available?有保護(hù)設(shè)置嗎？60.Panel board schedules配電盤(pán)面板清單61.Spare

16、 capacity available?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.Emergency/Standby power required?有應(yīng)急/備用電源嗎？64.VSD settings available factory/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 dr

17、awings in panels?配電盤(pán)的圖紙集67.Voltage warning labels?電壓警告標(biāo)簽 68.Ventilation sufficient?通風(fēng)充足嗎？69.Suitability for area - IP rating, GMP suitability, hazardous area classification.區(qū)域適宜性國(guó)際防護(hù)等級(jí)、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(hào)嗎？71.Do relief lines vent

18、 to a 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 adequately sized?放空線和泄放設(shè)備安全嗎?尺寸足夠大嗎？73.Are there any isolation valves which will inhibit operation of relief valves if closed? If YES, nominate Operations to monitor. If NO, record no.有處于關(guān)閉狀態(tài)會(huì)抑制放空閥操作的隔離閥嗎？如果有，請(qǐng)指定操作人

19、員對(duì)其進(jìn)行監(jiān)視。如果沒(méi)有，記錄無(wú)74.Is there a standard operating procedure for relief devices in place?現(xiàn)場(chǎng)有泄放設(shè)備的標(biāo)準(zhǔn)操作規(guī)程嗎？- For Field Verification- 現(xiàn)場(chǎng)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 situated within proximity of people insulated?位于人接近范圍內(nèi)

20、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(shí)和掛牌了嗎？79.Is there any rusted or damaged 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(tái)通道上安裝了止回門嗎？81.Review edge protection on platforms and heights. Will it protect perso

21、nnel and equipment? Is access adequate? 檢查平臺(tái)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 to people (slips), product (contamination of systems), or ingress to electrical switchgear or equipment?安全噴淋對(duì)人(滑跤的危險(xiǎn))、產(chǎn)品（系統(tǒng)的污染）或內(nèi)部的電氣開(kāi)關(guān)柜或設(shè)備產(chǎn)生危險(xiǎn)了嗎？83.Are safety showers supplied from tempered w

22、ater?安全淋浴供應(yīng)熱水嗎？84.Is chemical dosing within a safe proximity of 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 pipe lines標(biāo)識(shí)所有的管線86.Label all electric switches, disconnects, MCCs, control panels, cables, etc.標(biāo)記所有的電氣開(kāi)關(guān)、中斷器、電動(dòng)機(jī)控制器、控制盤(pán)和電纜87.Label vessels (material, hazard warnings)List:標(biāo)記容器（材料、危險(xiǎn)警告

23、）的清單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 posted92.Install appropriate area signs93.Is all scaffolding and equipment removed; is general housekeeping acceptable?94.If there is potential for entrapment or exposure, has an E-Stop

24、been provided?95.If full guarding is in place, has a lockable isolation device been provided?96.Pest control required in room/building?97.MSDS sheets required?98.Sprinklers in rooms?99.Single point of failure condition? Has it been identified? Record.PSSR Checklist Example A-2Pre-startup Safety Revi

25、ew ChecklistInspection Date:Department/Area:Project Number:Title/Equipment:Signatures below indicate acceptance that the equipment or project is safe and satisfactory to start-up with the exceptions noted.Engineering / MaintenanceDateEHS GroupDateQA GroupDateManufacturing / OperationsDateProject Eng

26、ineerDateProcess EngineeringDateChecklistItem No.Details (reference category/item no.)ResponsibilityCompleteSign & DateCategory A Action Items - Items to be completed BEFORE authorization and start-up.5.Category B Action Items - Items to be completed AFTER start-up..2.S

27、ign below only when all punch list “before start-up” items are completedAuthorized:Facility/Equipment Owner Signature:DatePSSR ITEM NO.CATEGORY/ITEM TO ASSESSNotApplicable1.1GENERAL SAFETY1.1.1Have ALL appropriate personnel (Operations, Maintenance, Technical, and Supervision) received adequate and

28、appropriate training on the equipment and operating procedures?1.1.2Has adequate and appropriate PPE (Personal Protective Equipment) been specified in the Work Procedures and/or Standard Operating Procedures. Has the PPE been provided?Have the PPE users been trained in the use of the PPE? Is the tra

29、ining documented?1.1.3Have measures been taken to adequately guard all dangerous parts of this equipment? 1.1.4Has sufficient provision been made for the electrical and/or mechanical isolation of the equipment?1.1.5Are points of isolation clearly marked/labeled and readily accessible?1.1.6Have bump/

30、trip hazards been properly identified and adequately marked? Have all sharp edges been removed?1.1.7Has proper guarding, handrails/barriers, been provided to prevent falls?1.1.8Have all hot/cold surfaces been adequately guarded to prevent burns? Are all cold surfaces adequately insulated to prevent

31、condensation drips (slip hazards)?1.1.9Are Safety Showers and Eye Wash facilities provided and adequately marked? Are the Safety Showers and Eye Wash facilities routinely inspected?Do the Safety Showers and Eye Wash facilities locations comply with Corporate guidelines?Are the Safety Showers and Eye

32、 Wash facilities readily visible and accessible? 1.1.10Has sufficient lighting been provided so that operation, servicing, maintenance, and repair of the facilities can be carried out safely?1.1.11Are notices, dials, screens, etc. for providing operational instructions, safety warnings, and emergenc

33、y information provided, if required, and positioned so that they are clearly visible and easily read? 1.1.12Have 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 properly secured?1.1.

34、13Are all of the applicable Work Permit Procedures (Confined Space Entry, Lock Out/Tag Out, Hot Work, High Work, etc.) in place? Have the Operating, Maintenance, and Supervisory personnel been properly trained on the Work Permit Procedures? 1.1.14Has the fire protection systems been inspected by the

35、 insurance company?Has acceptance testing been completed and documented?Is there an agreed on test and inspection program for the fire protection systems (including alarm systems)?1.2MACHINERY/EQUIPMENT SAFETY1.2.1Has the machinery/equipment been installed so that it will be stable and secure during

36、 operation?1.2.2Has all access to dangerous moving parts, or danger zones created by the equipment, been prevented by the provision of the correct guards, interlocks (both safety & non-safety) and/or barriers?1.2.3Have the correct safety measures been taken to prevent any risk from hot/cold surfaces

37、, ejection of material, failure of parts and their ejection, overheating/fire?1.2.4Has 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? Have slip, trip,

38、 trap, crush, entanglement, fall, bump, and cut hazards been minimized?1.2.5Is 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?1.2.6Is the equipment provided with a

39、 clearly identified means to securely isolate it from ALL energy sources?1.3ERGONOMICS1.3.1Have 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?1.3.2Has the

40、 need to lift, carry, push or pull heavy loads, or parts, been eliminated to the extent possible?1.3.3Are all display screens, dials and START/STOP/ EMERGENCY buttons positioned so that they are readily visible and accessible by the operating personnel?1.3.4Have Visual Display Screens been positione

41、d so that interference from glare is reduced to the minimum?1.3.5Have workstations been designed and equipped so that the operator can adopt a comfortable position? (That is, able to stand, or change position and sit upright, angle at elbows and knees 90, feet on floor.)1.3.6Does the operation of th

42、is equipment increase the risk of Upper Limb Disorder; for example, repetitive tasks, handling operations, machine paced work and prolonged operation?1.4OCCUPATIONAL HEALTH1.4.1Have all health risks arising from the gases, liquids, dusts, mists, biological hazards or vapors used by, contained in or

43、emitted by this equipment been assessed?Have the health risks been eliminated or are adequate engineering controls utilized to minimize the risks?1.4.2Has adequate RPE (Respiratory Protective Equipment) been specified in the Operating Procedures?1.4.3Has the need for an Occupational Health Monitorin

44、g Programme been assessed?Has a Monitoring Programme been scheduled?1.4.4Have the Operating Procedures been reviewed to take into account any additional “health hazards” which may arise from operation or maintenance of this equipment?1.4.5Has adequate LEV (Local Exhaust Ventilation) been installed,

45、tested, balanced, and entered on an Inspection Schedule? 1.4.6Have adequate inspection/cleaning ports been provided on ductwork?1.4.7Are relief facilities directed to a safe place away from the workplace?1.4.8Has a Noise Survey been considered and a Noise Compliance Plan prepared, if required?1.4.9H

46、as all insulation been identified? 1.4.10Has all pipe work, tanks, and equipment containing hazardous materials been adequately labeled?2.0PROCESS SAFETY2.1PROCESS TECHNOLOGY2.1.1Are up-to-date Material Safety Data Sheets available?2.1.2Have the hazardous effects of inadvertent mixing of different m

47、aterials been considered (that is, has a chemical interaction matrix been prepared/updated)? 2.1.3Has the process design basis been documented or updated?Has the control philosophy and sequence of operations been documented?2.1.4Has the equipment design basis (for example, BPFs/P&IDs) been documente

48、d/updated?2.1.5Have the recommendations from safety reviews, Process Hazards Analysis (PHA), Hazards and Operability Reviews (HAZOP), CHAZOP, or others, been implemented? Record any incomplete items.2.1.6Are all relief devices shown on the P&IDs?Are standard markings used on the relief devices?Are t

49、he relief/rupture pressures included on the P&IDs?2.1.7Have the pressure relief device calculations been provided?Was DIERS technology utilized to size the pressure relief devices for all pressure vessels?Does the sizing of pressure relief devices agreed with the calculated sizes?Do the calculations

50、 take into the downstream piping?2.1.8Do the relief devices vent to safe locations?Is containment provided for liquids and solids released from pressure relief devices?2.1.9Are there isolation valves that, if closed, will inhibit the operation of pressure relief devices?If yes, Operations must estab

51、lish control plans to insure that the isolation valves cannot inhibit the operation of the pressure relief devices.2.1.10Are all pressure relief devices included in the Preventive Maintenance Program? Are the inspection and testing of relief devices in accordance with local regulations?2.2MANAGEMENT

52、 OF CHANGE TECHNOLOGY/MANAGEMENT OF SUBTLE CHANGE2.2.1Has a management of change technology/subtle change document (for example, Change of Design - COD) been approved?2.2.2Has a test authorization been approved?2.2.3Are all action items, arising from the COD, that were deemed necessary for start-up,

53、 complete? 2.2.4Have all changes made during construction been recorded and authorized? Have hazards evaluations (PHAs, HAZOP, or CHAZOP) been done on all the changes made during construction?2.3PROCESS HAZARDS ANALYSIS2.3.1Have project PHAs been approved and a final project safety report been prepared?2.3.2Are all action items, deemed necessary by the PHA team for start-up, complete?2.3.3Has the project been approved as “Safe to proceed with” by the PHA team?2.4QUALITY ASSURANCE2.4.1Have checks and inspections been made