FORMAT/CHECKLIST/DATA SHEETS REV. NO.

: ‘0’
TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
SAFETY REVIEW
DOC. CODE

DEV7.3WI(Pr.2)CL(1) REF. TO LEVEL III DOC. DEV 7.3WI(Pr.2) PAGE 1 OF 11

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1.0 General
1.1 Establish the ‘abnormal’ operating
conditions and alternative operating modes as
1.
well as the steady state conditions throughout
the plant.
1.2 Make particular reference to the extremes
2. of pressure, temperature, flow, condensation in
cold lines etc.
1.3 Establish the basis for design condition
3. selection and the failure modes that could
jeopardize the plant integrity.
2.0 Material Selection
2.1 Ensure that the correct grade of material
has been chosen for the particular service, fluid
composition and condition by considering the
4.
proposed corrosion protection and corrosion
allowance, erosion, stream temperatures and
pressures.
2.2 Check the possibility of a hazard from
cross connection of equipment, e.g. A common
5.
venting or drain system or cross-connection of
safe and hazardous systems.
2.3 Check that failure of all process / utility
6. interfaces have been considered, e.g. heat
exchanger tube rupture.
2.4 What fire protection philosophy has been
7.
adopted?
2.5 Review commissioning and operating
8. instructions and maintenance isolation
procedures.
3.0 SPILLAGES
3.1 Are there facilities for dealing with
9.
chemical spillages?
3.2 Are bunds provided to contain any large
10.
Spillages of material
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
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3.3 Is adequate bunding of all storage tank

11.
areas provided?
3.4 Are tank bunds provided with suitable
12.
drainage systems?
3.5 Do the calculations for bund sizes and tank
13. separation comply with the appropriate safety
code?
3.6 If more than one tank is within a single
14. bunded area, are all the fluids stored non-
reactive?
4.0 HAZARDOUS OR REACTIVE
CHEMICALS
4.1 Can a hazardous material accumulate in the
15.
system?
4.2 Can a dilute material be concentrated to a
16.
hazardous concentration?
4.3 Is it possible for relative feed rates to
change so that the hazardous material is not
17. reacted fast enough? (This could allow
hazardous concentration to exist in the
equipment).
4.4 Can other materials back up into the
18.
hazardous material feed tank?
4.5 Can a hazardous material be contaminated
19. or get into other systems either through the vent
systems or other utility piping?
4.6 Is it possible for material to be trapped by
valves in an unvented or inadequately vented
20.
system and decompose or polymerize rapidly
while so confined?
4.7 Are lines containing toxic, highly
21. corrosive, volatile or otherwise hazardous
media identified?
22. 4.8 Are the safety aspects of the routing of
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
SAFETY REVIEW
DOC. CODE

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each line satisfactory?

4.9 Do they avoid fire hazard areas wherever
23.
possible?
4.10 Are all potential explosion hazards
24.
identified, located and classified?
4.11 Are vessels which will require explosion
25.
relief identified?
4.12 Is the extent of hazardous areas defined
26.
correctly with respect to the source of hazards?
4.13 Is the source of information on hazardous
27.
materials suitable and valid?
4.14 Are data extrapolations (if any)
28.
reasonable?
4.15 Is the isolation of hazardous fluids by
29. double block and bleed or line blind valves
adequate?
4.16 Are there adequate detection / warning
30. devices to protect against any possible
overheating that may cause a fire / explosion?
4.17 Is the possibility of a hazardous reaction
between the contents of one pipe leaking and
the contents of another pipe or vessel leaking
considered? E.g. acid and cyanide, water and
31.
sodium metal, volatile or flammable materials
and hot surfaces, water and strong acids. If any
such combinations exist, one of the materials
should be routed away from the other.
4.18 Some process lines which are located in
32. fire hazardous areas may require fire protection.
Have these been identified?
4.19 Are there detection and warning systems
against the presence of explosive, flammable, or
33. toxic atmospheres in confined spaces, e.g.
enclosures around fuel systems etc.
5.0 EFFLUENT
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
SAFETY REVIEW
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5.1 Are gaseous stack effluent and

34. concentrations listed, together with any toxic
characteristics?
5.2 Are liquid effluents run to a safe disposal
35.
system?
5.3 Have lists been prepared showing the pH,
36. toxicity, flammability, miscibility with water
and any special treatment required?
5.4 Can waste chemicals react with other waste
37. chemicals in the effluent disposal system and
cause difficulties?
5.5 Are effluents in open ditches liable to
38.
solidify?
39. 5.6 Is each solid waste product handled safely?
40. 5.7 Is any toxicity of solid considered?
41. 5.8 Is any special treatment required for solids?
5.9 Can gaseous effluent cause personnel
42. hazards in adverse wind or climatic conditions,
e.g. inversion
5.10 Does the discharge of effluent cause
43.
problems with the environment?
5.11 Are all the waste sumps and settlement
44. tanks located safely with respect to exposure to
fire and personnel safety?
6.0 TRIPS, CONTROL VALVES AND ESD
6.1 Do control valves fail to a safe state during
45. abnormal conditions? (I.e. a failure of
instrument air or Power)
6.2 Can gas break through when liquid systems
46. are let down?
6.3 Are there bypass valves round the control
47. valves? Can there be a source of gas break
through?
6.4 Are the differences between normal control
48. levels and trip levels both adequate and safe?
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
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6.5 Do the trip systems have emergency power

49. available to them during a failure of the normal
power supply?
6.6 Is Emergency Shut Down (ESD) logic
50.
established?
6.7 Do ESD valves move to a safe, preset
51.
position in the event of a failure?
6.8 Do the ESD valves close quickly enough
52. and are allowance made for any subsequent
hydraulic shock caused by the action?
6.9 Is there adequate capacity in the hydraulic
storage cylinder to operate all of the ESD
53.
valves to the safe position in the event of a
power supply failure?
6.10 Is sequential shut-down of equipment in
54.
emergency situations determined?
6.11 Do fired heaters have safety interlocks
55.
for startup, operation and shutdown?
6.12 Is control equipment interlocked to
56.
prevent unsafe operation?
7.0 VENTS AND DRAINS
7.1 Are there hazards from cross-connection of
57.
equipment, e.g. in common venting systems?
7.2 Is the vent and drain systems adequate?
58.
Confirm design basis.
7.3 Do the vent and drain systems have the
ability to vent equipment without pipes
59.
becoming blocked with either liquids or solids?
i.e., hydrate or ice formation during blowdown.
7.4 Is the back pressure on multi-vent systems
60. satisfactory? Presentation of back pressure
profile and calculation method is required.
61. 7.5 Are the seal systems on run down tanks of
adequate design to ensure a satisfactory seal
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
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during the time de-pressurizing is taking place?

7.6 Consider all vents which are discharging
non-flammable / non-toxic gases such as steam,
62. nitrogen or carbon dioxide. Has the highest
working platform that is within a small radius
of each vent been determined?
7.7 Is the top of each vent at a somewhat
63. higher elevation than this highest working
level?
7.8 Are harmless liquids (including vent line
64. drains) piped to the appropriate plant effluent
drain and disposal system?
7.9 Are the outlets of the open vent and drain
65. pipes positioned so that the discharge can be
seen?
7.10 Do the outlet pipes of enclosed
66. pressurized systems discharged to drain via a
sight glass?
7.11 Are the drains for hazardous or
flammable liquids or gases piped into a closed
vent system equipped with the appropriate
67. collecting vessels, scrubbing plant, or flare
stack? (E.g. solvents, methane, hydrogen
sulphide, phosgene)
7.12 Are all closed vent systems designed so
that the system pressure during operations is
68. low enough not to prevent the opening of any
relief valves, or limit the flow through them?
7.13 Are the atmospheric storage tanks
69. provided with adequate vents for breathing?
7.14 Are vacuum-pressure breather valves
(conservation vents) used on tanks with inert
70.
gas padding or which contain low vapour
pressure liquids?
7.15 Are floating - roof tanks used for volatile
71.
liquids?
72. 7.16 Are the vapour spaces of gas lift tanks
connected to a single tank serving as a gas
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
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holder? If so, are relief valves provided for all

the tanks in the system?
7.17 Are the heights of the vent stacks
adequate? Establish that sufficient gas
73.
dispersion and radiation checks have been
carried out.
7.18 Have precautions against adverse winds
74.
been taken?
75. 7.19 Are gaseous effluents safe?
7.20 Can gas pockets accumulate in the
76.
drainage systems?
7.21 Is there a separate drainage system for
77.
noxious fluids?
78. 7.22 Are vent and drain line slopes adequate?
7.23 Have all plant operating phases been
79. considered, i.e., location of jack up during
operation?
8.0 RELIEF SYSTEM
8.1 Are the calculations for the capacity and
80. the basis for the sizing of the relief systems
correct?
8.2 Are the pressure and temperature ratings of
81.
relief systems suitable for the conditions?
8.3 Is the inlet piping to relief valves short,
82. straight, without pockets and at least the same
line size as the inlet flange of the valve?
8.4 Have inlet piping pressure drops been
83.
calculated?
8.5 Is the discharge piping of relief valves
84.
larger bore than the inlet piping?
8.6 Are special supports required to cope with
either sudden heating / cooling of the pipe or
85.
instantaneous fluid reaction forces when the
relief valve lifts?
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
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8.7 Have the outlet piping pressure drops been

86.
calculated?
87. 8.8 Can the gas relief vent lines flood?
8.9 Have relief valves been fitted across the
inlet and outlet of positive displacement pumps
and compressors so that any overpressure
88. caused by downstream blockages does not
damage the machine? Diesel driven centrifugal
pumps should be similarly protected against
high pressure from overspeed.
8.10 Are any block valves installed on the
89.
inlet side of a relief valve?
8.11 Are they specified as ‘locked open’ and
90.
full bore?
8.12 Is a relief valve fitted on the cold side of
heat exchangers to prevent excessive thermal
91.
expansion where both the inlet and outlet of a
heat exchanger have block valves?
8.13 Can extremely low temperature
92. conditions arise from the operation of a vent
relief valve, i.e., the Joule-Thompson effect?
8.14 Is a vacuum breaker fitted on vessels
93.
where required?
8.15 Is the slope of the relief line to the Knock
94.
out Drum / Glycol Seal Pot adequate?
8.16 Blowdown systems should be provided
95. where excessive vessel temperatures could be
reached during fire relief.
8.17 Can process fluids solidify or polymerize
96.
in the relief valve inlet line?
8.18 Has the low pressure side of heat
97. exchangers been protected against failure of the
exchanger tubes?
98. 8.19 Where bursting discs have been fitted
upstream of relief valve, can their premature
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TITLE: CHECKLIST FOR PROCESS DATE: 05.11.2009
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failure be detected and can the vent system

process the instantaneous gas flow?
9.0 COLD CONDITIONS
9.1 Do all pipelines which are liable to frost
damage have facilities for draining or other
99.
protection? Note: Insulation is not normally
sufficient for a dead end pipe leg.
9.2 Are vessels and pumps adequately
100.
protected?
9.3 Are non-flow pressure legs on columns or
101. vessels either filled with anti-freeze or provided
with a means of heating?
9.4 Is provision made for dealing with the
102. possible condensation of gases in pipes and
pipelines?
9.5 Can the performance of materials be
103. affected by extreme s of ambient temperature
likely to be encountered at the site location?
10.0 MAINTENANCE
10.1 Are there sufficient drains from
104. equipment to allow them to be emptied for
maintenance?
10.2 Can the internal fittings of all vessels be
105.
installed, removed and maintained safely?
10.3 Is there provision for the venting,
106.
draining, purging and washing of each vessel?
10.4 A sufficient number of manholes for
107. inspection and maintenance must be provided,
located to permit easy access.
10.5 Is there provision for positive isolation
108.
for vessel entry, e.g. by removable pipe spools?

11.0 PIPING
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11.1 Can vapour locking of pump suction lines

109.
occur?
11.2 Are the effects of reverse-flow
110.
considered?
11.3 Do the pipe sizes ensure that the
111. recommended rates of flow prevent the build up
of static electricity in fluids?
11.4 Can pressure build up in any pipeline or
112.
equipment that has been isolated?
11.5 Is the requirement for ‘double block and
bleed’ valve arrangements, or line blind valves
113.
identified? (Note: Do not rely on thin spade
plates in the line for isolation).

114. 11.6 Are isolation valves provided?

115. 11.7 Are the types of isolation valve correct?

11.8 Is earthing against static electricity
116. complete? Consider for example the valve
handles on rubber seated ball valves.

11.9 Have lines where large transient flows

117.
can occur been identified, i.e., vent systems?

11.10 Are pipes passing through fire walls?

Check and request for re-routing where this
118. does not seem appropriate. Also, request for re-
routing to minimize number of fire wall
punctures
11.11 Fire water ring mains may use
sectionalizing valves or there may be two main
119.
pipes, in case of critical service like offshore
platforms.
11.12 Check whether one of these designs is
adopted. In the latter design, ensure that the
120.
two mains pipes are routed separately, not close
to each other.
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11.13 Check flow regime in pipes carrying

two-phase fluids, to avoid surging / plug
121.
formation and / or liquid accumulation in the
pipeline.
12.0 PERSONNEL SAFETY
12.1 Is control equipment interlocked to
prevent unsafe operation? (E.g. operating
122.
without guards in place on crushing machinery
or conveyors etc.)
12.2 Can the fire protection system endanger
123.
life, e.g. CO2 and halon flooding systems?
12.3 Is there an adequate supply of buffer gas
124. at sufficient pressure to prevent the ingress of
toxic fluids when machine is pressurized?
12.4 Are hot or extremely cold surfaces
125. insulated if they are within the reach of
personnel?
12.5 Are there adequate safety showers and
126.
eye wash fountains?
12.6 Are externally located safety showers and
127.
eye wash fountains heated?

12.0 AUTHENTICATION
PARTICULARS DESIGNATION SIGNATURE
PREPARED BY

REVIEWED AND
APPROVED BY