MMP-CKL-0009 Design - Safety - Review

This checklist is an attachment to "The Handbook of Chemical Process Engineering"
Checklist Number: MMP-CKL-0009
DESIGN SAFETY REVIEW (DSR) PROCEDURE

Note: DSR to be undertaken in a workshop environment facilitated by an experienced Process Engineer. All parts A, B and C and
Impact of Change under each field to be discussed and Actions / Recommendations agreed to reduce or eliminate potential HAZARDS
identified.
SITE CHANGE: SAFETY REVIEW WORKSHOP
SC TITLE:
ITEM CAN THE CHANGE AFFECT/CAUSE ACTION TO BE TAKEN TO REDUCE ACTION BY Response COMPLETED
YES
NO
Nr OR ELIMINATE HAZARD signature &
date
Part A : ACTION LIST X All Detail Design deliverables / EPI QK / Nominated Contractor
1 Process Conditions
1.1 Temperature
1.2 Pressure
1.3 Flow and Relief Rate
1.4 Level
1.5 Compatibility / Composition
1.8 Reaction conditions
2 OPERATING METHOD CHANGES

2.1 Start-up / Shut Down
2.2 Isolation / Maintenance Preparation
2.3 Operating procedure.

2.4 Emergency operation / Instruction
2.5 Control lay-out / Control Mode

2.6 Trip and alarms
2.7 Operating cost
3 ACCESS
3.1 Operation of equipment
3.2 Maintenance of equipment
3.3 Vehicles/cranes/hoists
3.4 Fire-fighting
3.5 Means of escape
3.6 Ladders and cat ladders
3.7 Walk-ways, Tripping Hazards
3.8 Handrails and machine guards
1 of 8 Rev. 0
identified.
SC TITLE:
YES
NO
date
4 ADVERSE CONDITIONS
4.1 Fire / Auto Ignition
4.2 Vapour Cloud / Explosion
4.3 Toxicity
4.4 Reverse flow
4.5 Under or over pressure
4.6 Increased/decreased temperatures
4.7 Increased/decreased flows

4.8 Increased corrosion/ erosion rate
4.9 Increased fouling rates
4.10 Contamination of other streams
4.11 Up/downstream units
2 of 8 Rev. 0
identified.
SC TITLE:
YES
NO
date
5 SAFETY EQUIPMENT
5.1 Fire-fighting and detection
5.3 Safety equipment for personnel
5.4 Occupational Heath and Hygiene
5.5 Snuffing and purging devices
5.6 Intrinsic safety devices
6 ENVIRONMENTAL CONDITIONS
6.1 Liquid effluent
6.2 Solid effluent
6.3 Gas / Toxic emissions
6.4 MSDS update
6.5 Noise - in plant/ at unit boundary
6.6 Waste: Reduce / Re-Use
6.7 Waste: Recycle / Removal
7 ELECTRICAL
7.1 Motors / MCC
7.2 Switchgear / Lock Out
7.3 Cables
7.4 Transformer loading in substation
7.5 Overall power requirement
7.6 Plant Outlet / Small Tools
7.7 Earthing and static electricity
7.8 Lightning protection
7.9 Motorised valves
7.1 Hazardous area classification
8 INSTRUMENTATION
8.1 Software: Control loops
8.2 Software: Logic
8.3 Hardware / Firmware
3 of 8 Rev. 0
identified.
SC TITLE:
YES
NO
date
8.4 VDU Configuration
8.5 Field Instrument
8.6 Restriction plates / Measurement
8.7 Analyser
8.8 Fire & Gas Detection
9 CIVIL AND STRUCTURAL

9.1 Bund wall sizes
9.2 Drainage to plant drains
9.3 Painting of equipment/ piping
9.4 Insulation of equipment/ piping
4 of 8 Rev. 0
identified.
SC TITLE:
YES
NO
date
9.5 Fire-protection of structures/ valves.
9.6 Require approved structural design
9.7 Plot plan approval / update
10 MECHANICAL
10.1 Pressure vessels and vessels
10.2 Piping & Supports
10.3 Valves, vent & drain
10.4 Check valves
10.5 Bursting discs / relief valves
10.6 Pump or Compressor
10.7 Fan or blower
10.9 Filters
10.8 Isolation/protection devices
11 SERVICES REQUIREMENTS
11.1 Plant Air / Instrument Air
11.2 Nitrogen
11.3 Cooling water
11.4 Fire-water
11.5 Steam/condensate/boiler feed water
11.6 Fuel gas

11.7 Electricity
11.8 Raw materials
12 ENGINEERING DETAILS / METHODS
12.1 Drawing: P&ID / Isometric / GA

12.2 Data sheet
12.3 Maintenance procedures
5 of 8 Rev. 0
identified.
SC TITLE:
YES
NO
date
12.4 Inspection procedures
12.5 Spares stocks
12.6 Construction constraints
13 BUSINESS RISK
13.1 Guarantee / Licensor /
13.2 Insurance / Operating Permit
6 of 8 Rev. 0
identified.
SC TITLE:
YES
NO
date
Part B : PUNCH LIST
14 PUNCH LIST
14.1
14.2
15 PRE-COMMISSIONING REPORT
15.1 Tie-ins as per line diagram.
15.2 Construction as per line diagram
15.3 Equipment inspected and tested
15.4 Safety and fire audit completed
15.5 Outstanding reservations completed
15.6 Handover to production agreed

Part C : COMPLETION REPORT
16 POST-COMMISSIONING
16.1 Site Change Registered
16.2 Data book received and reviewed.
16.3 Vendor manuals received
16.4 All DRAWINGS "As-Built" updated
16.5 Plant equipment register updated
16.6 Maintenance Strategies updated
16.7 Inspection requirement updated
16.8 Spares holding revised
16.9 SMP, Source documents updated
16.10 Task list & schedules updated
16.11 PFD, P&ID, Plot Plan updated
16.12 ILD updated
16.13 Area classification updated
16.14 Earthing schedule updated
16.15 Update status on MOC Database.
7 of 8 Rev. 0
identified.
SC TITLE:
YES
NO
date
16.16 Site Change Filed at Documentation Control
Name Date Signature

DSR Facilitator
Project Engineering Manager
Licensor / Customer Approver
8 of 8 Rev. 0

MMP-CKL-0009 Design - Safety - Review

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This checklist is an attachment to "The Handbook of Chemical Process Engineering"

Checklist Number: MMP-CKL-0009

DESIGN SAFETY REVIEW (DSR) PROCEDURE

2 OPERATING METHOD CHANGES

2.3 Operating procedure.

2.5 Control lay-out / Control Mode

4.7 Increased/decreased flows

9 CIVIL AND STRUCTURAL

9.6 Require approved structural design

9.7 Plot plan approval / update

11.6 Fuel gas

12 ENGINEERING DETAILS / METHODS

12.1 Drawing: P&ID / Isometric / GA

15.6 Handover to production agreed

Name Date Signature

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