Site Technical Practice

MAJOR Pre-Startup Safety Review (PSSR) Checklist

FACILITY:

IVANHOE - ORION ENGINEERED CARBONS

MOC NUMBER:

MOC TITLE:

ItemQuestionGroup / NAInitials

PIPING

1Piping is routed and valved according to the P&ID.Construction

2Inspect valves, flanges and spec breaks to confirm proper pressure rating and compatibility.Construction

3Piping and equipment has been inspected for damage, debris, integrity, and anodesOperations

4All critical piping systems have hydro, pneumatic or non-destructive testing completed and QA documentation has been reviewed.Construction

5Relief systems, PSV's, PCV's, vent piping, flare stacks, and vent booms are installed per construction dwgs.Construction

6All permanent blinds are in place; all temporary blinds have been removed. The blind list has been reviewed and approved.Operations

7Flange installations have been inspected for proper bolting, gaskets, isolation kits, and restriction orifices.Construction

8All purging, flushing, draining, and pickling complete.Operations

9All drains and sewers have been inspected for plugs and covers.Operations

10Proper installation, operation and orientation of valves (process, instrumentation, utility...) have been ensured.Construction

11All filters, screens, and strainers (temporary or permanent) are properly located and installed.Construction

12Piping systems have been reviewed allowing for equipment/facility blowdown and isolationConstruction

13Vents have spark / detonation arrestors, where appropriate.Engineering

14The integrity of all thermowells and bull plugs have been inspected.Construction

15Exhaust lines / vents are properly located away from air intakes, air conditioners, fans, sources of ignition, etc.Construction

16All block valves on the relief systems have been locked or car sealed open and are in a functional stateConstruction

17Lock open and lock closed valves have been inspected and are properly secured in their intended position.Construction

18All block valves have been reviewed for normal position (norm. open or closed) and handle has full travel.Construction

19All fail safe valves have been reviewed for proper action (fail open, fail close, fail unchanged); and location.Construction

CIVIL

20Structural steel installed to engineering design specifications.Engineering

21Supports required meet design structural engineering standards.Engineering

MECHANICAL

22All equipment meets design specifications.Engineering

23Mechanical equipment has been checked for proper alignment, lubrication, and rotation; functional checkouts have been performed on equipment and controls.Construction

24All equipment has been filled with proper fluids to the appropriate level and charged as necessary.Construction

25Adequate spare parts are available.Operations

ELECTRICAL

26Electrical Motors (check for proper rotation and heaters are connected).Construction

27All equipment and structures grounded and tested.Operations

28Electrical relays, circuit breakers, transformers, lighting and emergency power systems inspected and tested.Construction

29Controllers and disconnects are labeled if the device being controlled is not obvious.Construction

30All electrical equipment installed to design specifications.Construction

31All electrical seals have been packed and poured; all explosion-proof boxes, conduit covers are properly secured and all electrical connections tightened and checked.Construction

32Any equipment and associated breaker panels not to be used or not available for use are out of service. All lockouts are flagged, tagged and listed.Construction

33Rotating equipment trip points, especially over speed, have been checked and tested.Construction

34The UPS and/or emergency power systems have been tested.Construction

INSTRUMENTATION

35All instrumentation installed to engineering design specifications (API RP 14C)Engineering

36All electrical and pneumatic loop checks completed.Operations

37Interlocks (Electrical and Mechanical) have been reviewed and tested for proper operation.Operations

38All tubing and tubing fittings have been inspected for proper fit-up and leakage.Operations

39All instruments weatherproofed.Operations

40Emergency equip. alarms, communication equip, and shutdown devices calibrated, tested, documented and activated.Operations

41The fire and gas detection systems have been inspected and tested and are in auto mode.Operations

42All bypasses and jumpers on control or safety circuits have been removed.Operations

43PLC logic tested and documentation completed.Engineering

44Backup batteries at full charge.Operations

HEALTH AND SAFETY

45Safety equipment, including fire fighting devices, escape devices, safety showers and eye wash stations, have been inspected and reviewed for proper operation and location.Operations

46Ladders, handrails, and guards (rotating equipment and heat) constructed correctly.Operations

47Fire detection system has been reviewed for proper detector location and correct response / action.Operations

48All safeguards including signs (DANGER, HIGH VOLTAGE, KEEP OUT, HEARING PROTECTION REQUIRED), chains, safety equipment boxes, PPE boxes, etc. are installed and adequately stocked.Operations

49Area has been cleared of construction equipment, surplus equipment, combustible materials, extraneous tools, unused parts, scaffolding and empty drums.Construction

DOCUMENTATION

50All applicable permits and approvals have been received from regulatory agencies (MMS / USCG)Engineering

51Emergency response and evacuation procedures/plans updated, communicated, and in place.Operations

52Hazard analysis recommendations have been addressed and implemented.Engineering

53Flare System /PSV/ Ventilation System design basis updated.Engineering

54Safety information is complete and in place.Operations

55A start-up plan has been prepared and applied.Operations

56Written startup, operating and shutdown procedures are in place (SOPs).Engineering

57Training of affected personnel has been completed (operations, maintenance, emergency response, etc.).Operations

58All construction punch list items have been reviewed and completedConstruction

59Piping and Instrumentation Diagrams (P&ID's) redlined.Engineering

60Process Flow Diagrams (PFD's) redlined.Engineering

61Process and Safety Flow Diagrams (PSFDS) redlined.Engineering

62SAFE chart redlined.Engineering

63Fire and Safety Equipment Locations Plans redlinedEngineering

64Electrical Area Classification Plan drawings redlined.Engineering

65Electrical One-line drawings redlined.Engineering

66Structural and Isometric drawings redlined.Engineering

67MSDS files updated.Operations

68Weight Management Program impacts addressed.Engineering

69PS/IM program updated.Engineering

70Inspections and Maintenance requirements addressed in MAXIMO.Engineering

71All applicable vendor data updated. (i.e., mechanical, electrical, instrument, etc.)Engineering

72Pressure Equipment Pre Commissioning Form completed and sent to Operating Centre IM Specialist FormConstruction

APPROVALS

All Responses reviewed by and agreed to by:

Title/PositionNameDate

Title/PositionNameDate

Authorization to Startup

Title/PositionNameDate