Pre Startup Safety Review Page 1 of 16

Attachment-1: Process Safety Information

Title FT-15-308/09 on FFE’s AN lines Date: 12/5/2022

Magnetic Flow head installation on each
Project Name: FFEs
PSSR No.

Area/ Building: Prilling section Sub HSE No.

Sr. Action Remarks

1. Physical and hazardous properties of all materials documented.
2. Process design basis documented.

3. Design basis for equipment and safety devices documented.

(Also communicated to proprietor & readily available to operating personnel)
4. Equipment fabricated and installed according to specification.
Maintenance procedures and preventive maintenance program
5. are adequate to ensure mechanical integrity throughout life of
the process including the spares.
Operating procedures, safe practices, safety procedures and
6.
emergency procedures are adequate.
7. Training programs are in place for operators and mechanics.

8. Management of Change procedures to be used for all changes.

Process hazards analysis/process hazards review completed
9.
and recommended actions completed.
Emergency plan based on consequence analysis developed
10.
(people trained)
11. Incident Investigation and Reporting Procedure in place

12. Procedure in place for interaction with contractors in the area

Equipment design database updated after new equipment
13.
installation

Pre Startup Safety Review Team:

Interface Name Designation Unit/Section Signature Date
Team Leader M. Tanveer
Production Jibran Zahoor
HSE
Maintenance
Project
Inspection
Process
Electrical
Instrument

Note: PSI section has to be filled before the field audit and summary posted on Attachment IA
 Pre Startup Safety Review Page 2 of 16
Attachment-1: Process Safety Information
Sr. Deficiencies to be corrected before Responsibility Target Date
commissioning.
1

Interface Name Designation Unit/Section Signature Date

Team Leader

Area In charge
 Pre Startup Safety Review Page 3 of 16
Attachment-2: General Project Audit Checklist

Title
Project Name: Project No.
Equipment Name: Equipment Tag.
Area Building: Field Visit Date:

Field Visit By:

Process Information
Process Material Electrical
Name: Classification
Operating Operating
Pressure: Temperature:
Process Material
Hazards

Guidelines:
i. Checklist to be filled during/after field visit
ii. All the items to be evaluated with following criteria
Yes: When an item is completed to fulfill its requirement
No: When an item is required but not completed. Deficiency or recommendation to be
mentioned in Remarks Column
N/A: When an item is not applicable on specific case
Required for Startup: When an item is required before startup of facility/ Equipment
Req’d
Sr. Item Description Yes No N/A Remarks
for S/U
2.1. Process Safety Information Documentation
1 P&IDs Available and Updated
2 Isometrics Available and Updated
3 Design Documentation Completed
4 Instrument/ Interlock Drawing Updated
5 Electrical Cable Drawings Available
6 Underground Piping Drawings Available
Safety Critical Service Documentation
7
Updated
8 Safety Critical Devices List Updated
9 MSDS of Chemicals Approved & Available
2.2. Management of Change Documentation
Recommendations of all relevant Sub HSE
1
forums addressed?
Is HSE Documentation Complete &
2
Approved?
3 Test Authorization Available
 Pre Startup Safety Review Page 4 of 16
Attachment-2: General Project Audit Checklist

Req’d
Sr. Item Description Yes No N/A Remarks
for S/U
DCS Process Control Change authorization
4
Available (if required)
5 Venting Permission Approval in Place
6 “Do Not Touch” Exception Required
2.3. Process Hazard Analysis/ Review
Process Hazard Analysis/ Review
1
Conducted and Approved
All “Before Start up” Recommendations
2
Completed
Any “Before Start Up” Recommendation
3
Waived?
2.4. Procedures
1 Equipment Description available
Normal Operating (SOP’s) & checklists
2
available & approved
Initial Startup/ Commissioning Procedures
3
Available
4 Safe Operating Limits (SOL) of process
parameters defined
5 Emergency Handling Procedures Approved
6 Non Routine Procedures (isolation,
cleaning etc.) available
7 Carseal valves identified and list updated
8 Maintenance Procedures
9 Spill Control Procedure
10 Analyzer Maintenance/ Calibration
procedures
11 Instrument Alarm and set point list available
12 Building Safety Instructions available
13 Fire Prot’n Equipment (Sprinklers
Extinguishers etc.) Procedures Updated
14 Safety Shower/Eye Washes Procedures
Updated
2.5. Quality Assurance
Equipment is installed in accordance with
1
design specifications
2 Correct Materials of Construction used
3 Pressure/Hydro Test Completed
4 NDT testing completed and record available
5 Test pack documents available
6 Pre Commissioning (Blowing, Purging, Inert
Charging) activities completed to ensure
 Pre Startup Safety Review Page 5 of 16
Attachment-2: General Project Audit Checklist

Req’d
Sr. Item Description Yes No N/A Remarks
for S/U
system readiness
7 Third Party Inspection Records available
2.6. Piping and Equipment
1 Piping & Flanges are of Proper Rating
Gaskets & Bolts of Correct Type as per
2
Specification
3 Short/ Long Bolting Checked?
4 Supports as per Design Installed &
Sufficient to cater vibrations
5 Tracing Completed, Tagged & Identified.
6 Correct Insulation Provided for Intended
Service
7 Process/Service Connections Correct
8 Isolation Valves with Handles Available
9 Low Point Drains (LPD), Flushing & Purge
Connections Adequate for Maintenance
10 3-Way Valves Orientation verified
11 Relief Device Installed & Directed Properly
12 PSV Outlet Vent Lines Protected Against
Water Ingress
13 Shielding (Flanges, Valves) provided if
Required
14 Makeshift Devices (Extension Cords,
Ropes, Hoses etc) Eliminated
15 Nitrogen Piping Standards Followed
2.7. Rotary Equipment
1 Guards Installed
2 Lubrication and Alignment Complete
3 Correct Rotation Verified
4 Equipment Spare Parts Available
5 Equipment PM plans/ Records Available
6 Hydraulic Systems Installed Per Design and
Checked
7 Emergency Stop Provisions Available and
checked
2.8. Instrumentation
1 Pressure Gauges Installed as Required
2 Temperature Gauges Installed as Required
3 Loop Checking Completed
4 Valve’s Fail Safe Position Verified
5 Alarms & Instrument Checked
 Pre Startup Safety Review Page 6 of 16
Attachment-2: General Project Audit Checklist

Req’d
Sr. Item Description Yes No N/A Remarks
for S/U
6 Analyzer Checking Completed
7 Safety or Process Interlocks/ Alarms
Provided and Checked
8 Instruments Meets the Process Material
Requirements
9 Instrument Spare Parts Available
10 Instrument PM plans/ Records Available
2.9. Electrical Systems
Conformance to Hazard Area Classification
1
Checked
Grounding, Bonding/Lighting (Surge)
2
Protection Provided
3 Electrical Inspection Complete
4 Emergency Switches Installed
5 Conduits and Boxes Sealed
6 Out of Service Equipment De-energized
7 Electrical Spare Parts Available
8 Electrical PM plans/ Records Available
2.10. Structure
1 Doors, Ramps, Fire Doors & Walls
Exits Available (Routine, Emergency
2
Escape)
3 Traffic Flow, Door Swings OK
4 Safety Chains, Handrails, Guard Rails OK
5 Walkways, Ladders, Stairs OK
6 Floor Drainage, Curbs, Dikes Checked
7 Operations/Maintenance Platforms
Provided Where Needed
8 Overhead Hazards Removed
2.11. Painting & Labeling

1 NFPA-704 HAZ COM Provided

2 Painting/Safety Painting OK
3 Flow Directions marked
4 Instruments tagging OK (Transmitters,
Gauges, Panel boards, DCS)
5 Electrical systems tagged (Switches,
MCC’s Buttons and Local Disconnects).
6 Hi Voltages Labeled?
7 Hot Surfaces Marked?
8 Equipment marked (Tanks, Pumps,
 Pre Startup Safety Review Page 7 of 16
Attachment-2: General Project Audit Checklist

Req’d
Sr. Item Description Yes No N/A Remarks
for S/U
Condensers, Exchangers, Feeders,
Monorails, Hoists, etc.).
9 “Do Not Touch” Labels provided
10 Other (Nitrogen, Air) labels provided
2.12. Emergency Response Preparedness

1 Evacuation Alarms Available?

2 Safety Rules or Signs Installed
Safety Shower/Eye Washes available &
3
accessible
4 Fire Prot’n Equipment (Sprinklers
Extinguishers etc.) available & accessible
5 Spill Containment Facilities Satisfactory
6 Emergency Facilities available
2.13. Environment Considerations

Adequate provisions been made for

1
disposal of all wastes
2 Any Waste water treatment required
Any effect on existing Liquid or Solid waste
3
handling systems identified
4 Gaseous emissions identified and within
allowable limits
5 At source waste minimization been
adequately addressed?
2.14. General Items

Any inadvertent process mixing point

1
identified?
2 Any Hazard to Nearby Equipment/ Facility
Any Hazard from Nearby Equipment/
3
Facility
4 Accessibility for Maintenance/ Operations is
satisfactory
5 Lockout/Tagout Provisions in Place &
Training Complete
6 Any Tripping Hazards or Pinch Points
Identified?
7 Area and Spot Ventilation Adequate
8 Any Pest Control Requirement Identified
9 Noise Level Measured
10 Lighting Adequate/Emergency Lights
 Pre Startup Safety Review Page 8 of 16
Attachment-2: General Project Audit Checklist

Req’d
Sr. Item Description Yes No N/A Remarks
for S/U
Adequate
11 Special Operating Tools Provided Where
Needed.
12 Equipment Run-in.
13 Hidden/Stored Energy Sources Identified?
14 Mechanical/Contractor Cleaned up Area
15 Training of operations & services staff
satisfactory
16 Communication Equipment (walkie talkie,
Hot line, telephone etc.) available
17 Employee Communication Prepared.
2.15. Specialized Items
* To be filled by PSSR team as per requirement
1 .
2
3
4
5
6
7
 Pre Startup Safety Review Page 9 of 16
Attachment-2: General Project Audit Checklist

Sr. Deficiencies to be Corrected Before Startup Responsibility Target Date

1

Sr. Deficiencies to be corrected “After Startup” Responsibility Target Date

1

Interface Name Designation Unit/Section Signature Date

Team Leader
Production
HSE
Maintenance
Project
Inspection
Process
Electrical
Instrument
 Pre Startup Safety Review Page 10 of 16
Attachment-3: Instrument Project Audit Checklist

Title Date:
Project Name: PSSR No.
Area/ Building: Sub HSE No.

Sr. Item Description Yes No N/A Remarks

3.1. JB’s Inspection
1 JB complies with area classification?
2 New JB has a number painted on it.
Sealing of the JB door/cover satisfactory for light
3
rain.
4 Lugs properly pressed and terminated.
5 No loose connections. (check a few wires).
Shield not connected at inst. end and is
6
grounded at control system.
7 Proper tagging on all cables with core marker.
JB TB’s drawing placed in envelope in JB?
8
(Optional but preferable)
Cable’s entering JB properly glanded with no
9
opening for dust.
10 On JB's, no top entry for cables.
11 Any spare cable entry points have blind plug.
Segregated AC and DC signals keeping in view
12
voltage levels.
If any shared Inst / Elec signal, has checklist
13
given in I&E proc. been filled.
3.2. Control Valve Checks
1 Tag plate installed.
2 Tag name painted.
3 If valve safety critical, is it painted red.
Fail-safe position painted on valve? (e.g. A/C or
4
A/O)
5 Close IAS and check valve fail-safe.
6 Block and bleed available for isolation.
Hand jack auto to hand-jack and back to auto
7
procedure displayed?
Convenient access exists to hand-jack for
8
operator.
3.3. SOV Checks
Air bleed port faces down so dust cannot
1
accumulate.
2 Bug-proof installed.
 Pre Startup Safety Review Page 11 of 16
Attachment-3: Instrument Project Audit Checklist

Sr. Item Description Yes No N/A Remarks

No mixed fitting e.g. brass to SS. (If found,
3
rectify)
3.4. Cables
1 Cable trays are not overloaded.
Fire proofing of the cable trays in the required
2
area done.
Cables are away from steam-lines or other heat
3
sources.
Distance kept between instrument signal &
4
electrical cables
OT’s on conduits have T facing downwards so
5
water does not fill up.
3.5. General Field instrumentation:
1 Instruments installed as per area classification.
Instruments meet area max. ambient
2
temperature rating ?
If ambient rating near borderline is equipment
3
installed in shade.
4 Location allows easy access for maintenance.
5 Tag plates installed on instruments.
6 Tag name painted onto instrument.
Isolation / depressurization arrangement
7
provided (Block & Bleed)
Check IAS supports leading to device are firm
8
and sturdy.
If any spare thermo wells or tapings, plugged and
9
blinded properly?
If sq. root required, configure only in DCS, not in
10
transmitter.
3.6. Special Instructions to Operator:
Any special procedure to take equipment in
service, has been put up? (e.g. If new control-
1
valve with spring loaded glands, pressurize
slowly.)
Checklist for recording post - commissioning data
2 (reference & initial observation) has been
developed?
3.7. Control System:
In Control system (DCS, PLC) cabinet, check
1
terminations
Have new points and schematics been
2
configured and verified
 Pre Startup Safety Review Page 12 of 16
Attachment-3: Instrument Project Audit Checklist

Sr. Item Description Yes No N/A Remarks

Have you taken a fresh backup after the
3
changes, irrespective of backup frequency?
Check for free I/O space on the system, if none
4
inform area engineer

Sr. Deficiencies to be Corrected Before Startup Responsibility Target Date

1.
2.
3.
4.
5.
6.
Sr. Deficiencies to be corrected after “startup” Responsibility Target Date
1.
2.
3.
4.
5.
6.

Interface Name Designation Unit/Section Signature Date

Team Leader
Production
HSE
Maintenance
Project
Inspection
Process
Electrical
Instrument
 Pre Startup Safety Review Page 13 of 16
Attachment-4: Electrical Project Audit Checklist

Title Date:
Project Name: PSSR No.
Area/ Building: Sub HSE No.

Sr. Item Description Yes No N/A Remarks

4.1. General Items
Has I&E Sub-SOC been held for the project (if
1 required)

2 Electrical Single Diagram Updated

3 Under ground Electrical drawing Updated
4 All relevant control schematics updated on CAD
In case of MV cable termination or jointing, Box
5 up certificate obtained
In case, any instrument signal coming to
6 Electrical circuit or vice versa, verification check
list as given in I&E procedure is duly filled
In case any protection devices are employed,
these are bench tested & circuit integrity has
7 been checked by a dummy test from the sensor
to final trip element.
All isolating breakers have proper lock out and
8 tag out arrangement
Checklist for recording post-commissioning data
9 (Reference & initial) has been developed.
10 Area illumination is sufficient.
11 Smoke detectors are installed where required.
12 Air-conditioning is sufficient where required.
4.1. JB’s / DB’s Inspection
1 JB / DB complies with area classification?
2 New JB / DB has been tagged properly.
3 JB / DB is properly grounded.
Sealing of the JB / DB carried out against water
4
ingression.
Lugs properly pressed and terminated.(spot
5
check few)
No loose connections at terminals & joints. (Spot
6
check a few wires).
Proper tagging of all cables with core marker
7
available.
JB TB's drawing placed in envelope in JB?
8
(Optional but preferable)
Cable's entering JB properly glanded with no
opening for dust.
Any spare cable entry points have blind plug.
 Pre Startup Safety Review Page 14 of 16
Attachment-4: Electrical Project Audit Checklist

Sr. Item Description Yes No N/A Remarks

No un insulated bus bars / joints.
No left over material & tools present inside.
Secondary winding of CTs, if used, is grounded
at one end.
cables , entering or leaving metallic conduits are
protected from sharp edges
Fire catching material like paper, wood is not
present inside.
4.2. Cables / Conduits / Fittings
1 Cable trays are not overloaded.
Fire proofing of the cable trays in the required
2
area done.
Cables are away from steam lines or other heat
3
sources.
Distance kept between instrument signal &
4
electrical cables
OT's on conduits have T facing downwards so
5
water does not fill up.
6 Sealing of conduits done
7 Armour is grounded at one terminal point
Cable bending radius is as per manufacturer's
8
recommendations.
Conduits for cables, if used, are chosen in a
9 manner to ensure recommended free space
(40%) within the conduit.
Cable route markers installed & protruded on
10
surface.
11 Lugs are properly punched at core conductors.
4.3. Motors/ Transformers
1 Motor is as per area classification
Motor name plate matches with actual
2
requirement.
Motor / Transformer is grounded at two different
3
points on its body
4 Check free rotation of motor before switching ON
5 Coupling guard is installed at motor coupling
Dummy test of Motor control circuit carried out
6
before switching it ON
All accessories of transformers are mounted and
7
fitted on its body
Functionality of Bucholz relay is established
8 through dummy test before switching ON the
transformer.
9 Silica jell is filled in breather and its color is blue.
 Pre Startup Safety Review Page 15 of 16
Attachment-4: Electrical Project Audit Checklist

Sr. Item Description Yes No N/A Remarks

4.4. Special Instructions to Operator:
Any special procedure to take equipment in
1 service, has been put up?

Sr. Deficiencies to be Corrected Before Startup Responsibility Target Date

1.
2.
3.
4.
5.
6.
Sr. Deficiencies to be corrected “after startup” Responsibility Target Date
1.
2.
3.
4.
5.
6.

Interface Name Designation Unit/Section Signature Date

Team Leader
Production
HSE
Maintenance
Project
Inspection
Process
Electrical
Instrument
 Pre Startup Safety Review
Attachment-5: Test and Startup Authorization Page 16 of 16
Form

Title HS Ejector Revival Date: 7/26/2021

Project Name: HS Ejector Project No.
Area/ Building: CAN Plant PSSR No. CAN-2021-04

Sr. Deficiencies to be Corrected Before Startup Responsibility Target Date

1 Operational procedure to be developed UM CAN 27-07-2021
2 Conduct Training of staff on operational procedure. UM CAN 06-08-2021
3 Provide Insulation on HS & MS steams lines AE Craft 28-07-2021
4 PIC 15-257 & TIC 15-132 stroking to be checked. AE Instt. 27-07-2021
5 Check complete loop of PIC 15-257 & TIC 15-132 AE Instt. 27-07-2021
6 Instrumentation of 15-257 & 15-132 to be checked. AE Instt. 27-07-2021
7 Block valves & gaskets to be checked. AE FM 27-07-2021
8 Butt list of the circuits to be filled UM CAN 28-07-2021
9 PSV 1506 calibration is already done in TA 2021. AE Insp. Completed
10 First hour checklist to be updated UM CAN 30-07-2021

Test Authorization:
Date
Area Unit Manager

Equipment Startup Authorization:

Startup of Equipment Authorized by
Date
Area Unit Manager

Project Closure:
All the recommendations listed in the PSSR have been completed .

Date
Area Unit Manager
Dispatch List:
 Production unit/ equipment owner – original copy
 Copies to be sent to
o Project Engineering
o HSE
o All member units.