sample pre-startup safety review checklist

Sample supplied by P. S. Rawat

Contact for more inputs on Env., Health & Safety related issues

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Pre-Startup Safety Review Checklist New Plant

[A] SAFETY

Particular YES NO REMARKs

1. Conducted HAZOP or similar safety study for the process.

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,




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 fittings.

31. The vents of the reactors should also be fitted with flame arrestors and the vent should be above 3 mtr. of the roof.

32. Entry and exit access to the plants must be clear of any obstructions.

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 workplace)

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.




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

4. All motors in flammable solvent handling/storages area shall be flameproof/weatherproof type.

5. All bulk storage tanks in the process area should have dykes around them.

6. 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.




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.

[F] TRAINING: 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.

sample pre-startup safety review checklist

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