HSE - 5.7 Procedure For Pre-Startup Safety Review Management

CNPC International
Doc. Title: Procedure for Pre-startup Safety Review

Management
Doc. Type: Procedure
Custodian: Corporate HSE Department
Doc. No.: CNPCI Corp HSE 6.5

Revision: 2.0
Issue Date: July 2012
Table of Contents
1. Objectives, Scope and Application ................................................................................... 1
1.1 Objectives ..................................................................................................................... 1
1.2 Scope ............................................................................................................................ 1
1.3 Application ................................................................................................................... 1
2. Relevant Documents ........................................................................................................... 1
3. Terms and Definitions ........................................................................................................ 1
4. Responsibilities ................................................................................................................... 2
5. Management Requirements .............................................................................................. 2
5.1 Basic Requirements ...................................................................................................... 2
5.2 Establishment of PSSR Teams ..................................................................................... 3
5.3 Items for Review .......................................................................................................... 4
5.4 Process .......................................................................................................................... 5
5.5 Document Filing ........................................................................................................... 7
5.6 Assessment ................................................................................................................... 7
6. Audit, Renewal, Deviation and Training and Communication ..................................... 7
6.1 Audit ............................................................................................................................. 7
6.2 Renewal ........................................................................................................................ 7
6.3 Deviation ...................................................................................................................... 8
6.4 Training and Communication....................................................................................... 8
Appendix A PSSR Checklist (applicable to system overhaul and maintenance without
changes) ....................................................................................................................................... 9
Appendix B PSSR Checklist (applicable to new, modified and expanded systems and
systems subject to changes) ..................................................................................................... 13
Appendix C PSSR Checklist (applicable to safety review before spud-in) ..................... 28
Appendix D PSSR Checklist (applicable to safety review before penetrating into oil
and gas formations) .................................................................................................................. 39
Appendix E PSSR Report (sample) .................................................................................... 41

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1. Objectives, Scope and Application
1.1 Objectives
This procedure is intended to standardize the safety review of installations, equipment,
facilities and processes before startup to ensure all the aspects which may prevent them from
operating in a safe and environmental friendly way are identified and adequate safety controls are
in place before startup.
1.2 Scope
This procedure specifies the requirements for pre-startup safety reviews and for relevant audits,
renewal, deviations, training and communication.
1.3 Application
This procedure applies to the safety review activities for installations, equipment, facilities and
processes before startup.
This procedure applies to Headquarter of CNPC International (hereinafter referred to as
CNPCI), Regional Companies and Operating Companies under the direct management of CNPCI
(hereinafter referred to as all companies), as well as all the contractors and suppliers providing
services to CNPCI Headquarter and all companies. Operating companies for which CNPCI has
operational control shall implement this procedure or formulate their own procedures or
implementation processes for pre-startup safety review management according to this procedure,
incorporate them into the HSE management system of their own and strictly enforce compliance.
Operating companies for which CNPCI has joint or no operational control shall formulate
corresponding procedures with reference to this procedure. In case of any conflict between this
procedure and the laws, regulations, standards and specifications applicable in the host country,
the procedure to be implemented shall be developed upon the consensus of all the partners of the
joint venture.
2. Relevant Documents
2.1 CNPC Corporate Standards

Q/SY 12452009 Specification for Pre-startup Safety Review Management
2.2 CNPCI Corporate HSE Management System
HSE 2.0 HSE Management System Manual
HSE 6.8 Procedure for Process and Mechanical Change Management
HSE 4.9 Procedure for Process Hazard Analysis Management
3. Terms and Definitions
3.1 Pre-Startup Safety Review (PSSR)

The process to review all the aspects which may prevent installations, equipment, facilities or
processes from operating in a safe and environmental friendly way, ensure adequate safety
controls are in place and all deficiencies requiring prior correction are corrected before startup,
and then grant startup approval.
3.2 Deficiencies Requiring Prior Correction
Deficiencies which are identified in the PSSR to be deviated from the design or operating
codes and/or standards, may result in serious damage during or after start-up and threaten the
safety and must be corrected before start-up.
3.3 Remaining Deficiencies
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Deficiencies which are identified in the PSSR to be deviated from the design or operating
codes and/or standards, wont hamper safe start-up of processes and equipment, but may have
negative impact on start-up efficiency and product quality and result in safety and/or
environmental accidents during operation, and could be corrected after start-up.
3.4 Area or Unit Chief
A manager responsible for the operation safety of the process or equipment to be started, such
as the head of a plant.
4. Responsibilities
4.1 Corporate HSE Department of CNPCI is responsible for formulation, management and
maintenance of this procedure.
4.2 HSE management committees at all levels are responsible for reviewing and approving the
plans and resources for the development, revision, communication, training and implementation
of the Procedure for Pre-startup Safety Review Management, and for auditing and monitoring the
overall implementation of the procedure to ensure the quality of the implementation.
4.3 Corporate functional departments of CNPCI are responsible for facilitating the promotion
and implementation of this procedure.
4.4 All companies shall formulate, manage and maintain their respective pre-startup safety
review management procedures according to this procedure. Relevant functional departments of
all companies are responsible for the implementation of the procedures and shall provide
corresponding training, supervision, measurement and assessment.
4.5 HSE departments of all companies are responsible for providing consultancy, support and
audit for the implementation of their pre-startup safety review management procedures.
4.6 All grass-root units (plants, stations, crews, workshops, installations and facilities) shall
implement the pre-startup safety review management procedures of their companies and provide
suggestions for improvement of the procedure implementation.
4.7 All relevant staffs shall receive training for pre-startup safety review, implement prestartup safety review management procedures, participate in audits for pre-startup safety review,
and provide improvement suggestions.
5. Management Requirements
5.1 Basic Requirements

5.1.1 Pre-startup safety review spans through project transfer and system operation. It is
designed to identify all the aspects which may have impact on the safe operation of processes and
equipment to ensure the following conditions are satisfied:
construction and installation of equipment is in accordance with design specifications and
established standards;
procedures to guarantee the safety operation of equipment, such as safety, operation,
maintenance, and emergency procedures, are in place;
appropriate process hazard analyses have been completed and all the recommendations
have been either implemented or addressed in a reasonable manner;
management of change has been followed and process safety information havebeen
updated;

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each employee involved in operation or maintaining the process or equipment has been
adequately trained and acquired the required certifications;
All the requirements about process safety management have been met and all the
deficiencies requiring prior correction have been resolved and such resolutions have been verified.
5.1.2 Pre-startup safety review is a prerequisite for project commencement. Projects requiring
PSSR include but are not limited to:
New, or modified or expanded systems (including leased systems);
Modified processes or equipment which involve flammable, explosive, toxic or hazardous
materials and high temperatures and high pressures;
Facility shutdown and overhaul projects;
Spudding or penetrating into oil and gas bearing formations or abnormally high pressure
formations;
Adoption of new processes or new technologies;
Other projects such as restarting the operation of oil or gas plants or stations.
5.1.3 PSSR teams should be built according to the authorization level of the specific projects
and conduct PSSR according to the checklists prepared in advance.
5.1.4 Considering the scale and work schedule of a project, PSSR may be conducted multiple
times in different stages and by focusing on different areas.
5.2 Establishment of PSSR Teams
5.2.1 Team Composition
5.2.1.1 To guarantee the quality of a PSSR, a PSSR team should be established in advance
according to the project schedule. A team leader should be designated depending on the
authorization level of the project concerned (usually the project manager, production manager or
chief engineer will act as the team leader). The team leader then proceeds with team member
selection and work assignment.
5.2.1.2 A PSSR team may be consisted of employees specializing in process technology,
equipment, inspection and maintenance, electric instruments, main operation and human resource
as well as HSE professionals. The team should also include representatives from the contractors,
parties involved in construction, design and supervision, and external experts with special
expertise and experiences.
5.2.2 Work Assignment
Area or Unit Chief
establishing the PSSR team and providing professionals and other resources required by
the PSSR of project;
leading the development of PSSR checklists together with the PSSR team leader;
chairing the PSSR planning meeting and review meetings;
reviewing the resolutions for all deficiencies requiring prior correction and approving the
startup of projects for which he/she has authority over upon confirmation together with the PSSR
team of the completion of the correction of all deficiencies requiring prior correction;
supervising, inspecting and following up the completion of the correction of remaining
deficiencies;
providing adequate resources for the implementation of all the safety and environmental
measures before startup;
ensuring all employees have received training in the PSSR management procedure.
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PSSR Team Leader

developing and implementing the PSSR plan;
organizing the PSSR planning meeting and review meetings, revising and improving the
PSSR checklists;
deciding on work assignments for team members and the work schedule;
leading the PSSR and taking the responsibility for the quality of the PSSR;
tracking and verifying the progress of the correction of all deficiencies requiring prior
correction;
preparing all the records and documents of the PSSE and filing them as required;
obtaining support for professionals from the higher management as necessary.
PSSR Team Members
attending the PSSR planning meeting and review meetings;
participating in preparation of PSSR checklists and conducting the PSSR against the
prepared checklists;
verifying the solutions for all deficiencies requiring prior correction and for remaining
deficiencies;
confirming the completion of the correction of all deficiencies requiring prior correction.
Process Safety Management Coordinator
Production Department or Operation Department may appoint a person who has received
training in process safety and risk management, process safety analysis and PSSR and is familiar
with process safety analysis methods to act as the process safety management coordinator of the
project to be responsible for
coordinating and guiding the preparation of the PSSR checklists by the production and
operation units
organizing the training in PSSR implementation methods
coordinating the implementation process of a PSSR
reviewing completed PSSRs for integrity and contents
assisting in preparing and filing the documents of PSSRs
HSE Professionals
participating in the preparation of JSST checklists;
assisting in staff training in PSSR;
participating in the inspection for specialized HSE facilities and the review for the
implementation of HSE requirements.
5.3 Items for Review
The PSSR team shall prepare the PSSR checklists together with the process safety
management coordinator, taking into account the nature of the operation, the characteristics of the
process and equipment, etc. The PSSR checklists in Appendix A, B, C and D may be referred to
and items for review may be added or revised as necessary. The checklists should cover process,
technology, personnel, equipment, accident investigation, emergency response, environmental
protection, etc.
5.3.1 Process and Technology
All the process safety information (e.g. material safety data sheets, process equipment
design basis, plot plans, piping & instrument drawing, certifications, etc.) have been updated and
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filed;
Process hazard analysis recommendations have been implemented;
Operation procedures, operation cards and relevant safety requirements comply with the
requirements for processes and technologies and have been approved;
Changes to processes and technologies, including changes to processes and instrument
drawings, have been approved and recorded;
Public utilities are ready for the startup of the project;
The production and operation command system functions well.
5.3.2 Personnel
All staffs involved have received trainings about the startup plan, HSE hazards, operation
procedures, maintenance procedures, safety specifications and emergency response;
Contractor staffs have received HSE training corresponding to their work, including
hazards of potential fire, explosion or release of toxic substances in the workplace or the
surrounding area as well as emergency response;
Newly hired or transferred staffs are clear about the possible risks associated with their
work and are competent in their work.
5.3.3 Equipment
Equipment has been made, transported, stored and installed according to design
specifications;
Equipment inventory and records of equipment operation, inspection, repair and
maintenance have been established as required and items, procedures and frequencies for
equipment testing and inspection comply with the relevant requirements;
Risks caused by changes to equipment have been analysed, procedures to guarantee the
safety of equipment startup and operation, such as equipment startup plans, operation procedures,
maintenance procedures, safety specifications and emergency response plans, have been updated
and distributed to relevant people and the provisions in HSE 6.8 Procedure for Process and
Mechanical Change Management has been followed.
All the other auxiliary systems are ready.
5.3.4 Incident Investigation and Emergency Response
Corrective measures based on lessons leant from previous incidents have been
implemented;
Emergency response plans are in consistency with process safety information and staffs
involved have received training about emergency response plans.
5.3.5 Environmental Protection
Emission and discharge reduction equipment can operate normally;
Waste (including commissioning wastes and defective products) treatment practices have
been determined;
Environmental incident response procedures and resources (people, equipment, materials,
etc.) are in place;
Environmental laws, regulations and standards applicable in the host country and the
environmental policies and procedures of the Company are complied with.
5.4 Process
5.4.1 Planning Meeting
The Area or Unit Chief and the PSSR team leader shall call all team members for the PSSR

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plan meeting. The main contents of the meeting are as follows:

A general introduction to the project by the PSSR team leader;
A clear definition of the work scope of the PSSR;
Review of the contents of the PSSR checklists;
Work assignments to individual team members by the PSSR team leader;
Development of the PSSR schedule;
Establishment of a mechanism for coordination with relevant parties involving in
engineering design, construction, etc., and other resource support.
5.4.2 Implementation of the PSSR
5.4.2.1 PSSRs include both document reviews and site inspections. PSSR team members shall
review against the PSSR checklists item by item according to their work assignments and
document all the findings with clear indications of the items reviewed, locations where the
reviews are conducted and people who perform the reviews.
5.4.2.2 To guarantee the quality of a PSSR, before the equipment installation work is
completed, preparation for the PSSR should be started, PSSR checklists should be developed and
the PSSR may be conducted for multiple times by stages and by disciplines according to the
construction progress of the project. All the issues identified from the reviews should be reported
to departments concerned for a timely solution. It will be too later to start the PSSR after the
completion of construction of the project.
5.4.3 Review Meetings
5.4.3.1 Having completed the review of all the items in the PSSR checklists, the PSSR team
leader and the Area or Unit Chief shall call all team members for the PSSR review meeting to
present and analyse the results of the PSSR: team members report their findings from the PSSR,
conduct process safety analysis to each finding, divide the findings into deficiencies requiring
prior correction and remaining deficiencies, draft a PSSR report and confirm the items to be
corrected before and after the startup and the deadline for such corrections to be made.
5.4.3.2 A PSSR report shall include the following:
The date of the report and an identification of the covered process and equipment, the
process safety information, and standard operating procedures reviewed;
An identification of the codes and standards upon which the covered process design and
operations were based;
The names of the persons who performed the safety review; and
Deficiencies from the design and operating codes and standards which were found during
the PSSR and shall be corrected before or after the startup with an appropriate description of the
resolution of each deviation finding;
Signatures of people for confirmation or approval and report distribution records.
Refer to Appendix E for a sample of a PSSR report.
5.4.3.3 For a PSSR implemented several times by stages and by disciplines, a holistic PSSR
review meeting shall be held before the startup of the project to sort, review and reconfirm the
PSSR results from all the reviews performed and a comprehensive PSSR report shall be drafted
on this basis.
5.4.4 Follow-up and Approval of Startup
5.4.4.1 Departments concerned shall bring forward deviation correction requirements in the
form of hazard elimination notices or non-compliance correction reports and track and verify the

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results of the corrections. Production and operation departments shall supervise the process of
PSSRs.
5.4.4.2 All deficiencies requiring prior correction must have correction plans including
corrective measures, responsible person(s) or units, schedules for correction and deadlines for
correction completion. The Area or Unit Chief should hold regular (generally once a week)
review meetings together with the PSSR team to follow up the progress of the correction of
deficiencies requiring prior correction until they are all corrected.
5.4.4.3 Upon completion of the correction of all deficiencies requiring prior correction, the
Area or Unit Chief should review the correction results with the PSSR team. Upon acceptance of
the correction results, the PSSR team leader should confirm in the PSSR checklists and report
and pass them to the Area or Unit Chief.
5.4.4.4 The Area or Unit Chief may approve the PSSR report only after having confirmed that
all deficiencies requiring prior correction have been corrected and all remaining deficiencies have
got monitoring measures and correction plans with designated responsible person(s) (or units)
and deadlines for completion. For a project sponsored by the area or unit itself, the project may
be started upon the approval of the PSSR report. For a project sponsored by the upper level of
management, the approval of the PSSR report by the Area or Unit Chief is a pre-requisite and a
primary condition for the startup and acceptance of the project.
5.4.4.5 After project startup, the PSSR team leader and the Area or Unit Chief should continue
to track the progress in the correction of remaining deficiencies and make acceptance upon the
completion of their corrections. After acceptance, the PSSR team leader should record the date of
completion on the PSSR checklists and report.
5.5 Document Filing
All the documents concerning the PSSRs performed, including PSSR checklists, PSSR reports,
correction plans for remaining deficiencies and follow-up plans, shall be filed.
The drawings, design documents and other data for deficiencies involving changes should be
updated and filed.
Upon completion of the correction of remaining deficiencies, the responsible person should
send a written notice to the Area or Unit Chief. The written notice should be filed together with
the PSSR checklists, PSSR reports and process hazard analysis reports of the project to ease
future document searches.
5.6 Assessment
After completion of a PSSR, the process safety management coordinator should assess the
PSSR performed for integrity and contents.
6. Audit, Renewal, Deviation and Training and Communication
6.1 Audit
CNPCI Headquarter and all companies shall audit the management of pre-startup safety review
as an important part of their HSE audit programs and may conduct audits solely focused on the
implementation of the procedure if necessary.
6.2 Renewal
This procedure shall be reviewed and revised by its custodian as necessary and, at a minimum,
not later than five years from the date of the last revision.

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6.3 Deviation
All companies shall report to Corporate HSE Department of CNPCI for any deviation from
this procedure in their own pre-startup safety review procedures. Any deviation in the
implementation of the procedure shall be authorized by direct supervisors. Deficiencies shall be
documented and the documentation must include the relevant facts justifying the deviation
decision. Deviation authorization must be renewed annually.
6.4 Training and Communication
This procedure should be communicated throughout CNPCI. All relevant staff, including
contractor workforce, should be provided training as appropriate. Training records must be
maintained.

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Appendix A PSSR Checklist (applicable to system overhaul and maintenance

without changes)
Table A PSSR Checklist
(applicable to system overhaul and maintenance without changes)
Production Unit / Equipment

Brief description of the overhaul and maintenance project
The whole category is not applicable
Remove all unnecessary materials used in

overhaul and maintenance
Select
Irrelevant
Deficiencies requiring actions
Relevant
Remaining
deficiencies
Deficiencies
requiring prior
correction
Review results or
requirements for
correction
1. Operating platforms / scaffolds

2. All items removed as wastes or replaced
after maintenance
3. Hydraulic test equipment and other
temporary equipment
4. Temporary connection pipes, hoses, power
lines, signs/markings, etc.
5. Leftover and unnecessary materials for
maintenance
6. Other materials that need clearing
Fire fighting devices and safety facilities
Select
Irrelevant

Relevant
7. Inspect or test fire fighting devices and

safety facilities.
8. Replace or repair lost or damaged fire
fighting devices and safety facilities identified
during inspections or testing.
9. Record the inspection and test results of fire
fighting devices and safety facilities as
necessary.
10. Check if all measuring instruments and
meters are verified correctly by authorized
agencies, within their valid periods and have
correct indications.
11. Check if all safety protection facilities are
restored.
12. Check if all relevant warning signs are
restored.
Remaining
deficiencies
Deficiencies
requiring prior
correction
Review results or
requirements for
correction

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Table A (Continued)
Check process pipelines and equipment

overhauled or maintained
Select
Irrelevant
Relevant
1.3 Check the shutdown process record of

critical equipment, confirm that the person
responsible for the equipment has signed
and filed the record and confirm if the
shutdown process complies with the
shutdown procedure.
14. Install all plugs (screw plugs or blind
plates) properly
15. Confirm that all valves are set at correct
positions.
16. Check the air-tightness of all connection
parts related to the maintenance.

Deficiencies
Remaining
requiring prior
deficiencies
correction
Review results or
requirements for
correction
17. Check the blind plate checklist and

attach a signed copy of the checklist to this
report
Flanges
Select
Irrelevant
Relevant

Deficiencies
requiring prior
correction
Remaining
deficiencies
Review results or
requirements for
correction
18. Check the tightness of all bolts.

19. Check if bolt gaskets are appropriate and
complete.
20. Check if flange gaskets are placed at
correct positions.
21. Check if flanges have any damage.
Valves
Select
Irrelevant

Relevant
22. Does replacement or adjustment of

packing meet the requirement?
23. Check if packing is sufficient.
24. Check if valves are set at correct
positions.
25. Conduct and confirm loop tests on
control valves.
26. Check if travels and failure positions of
all control valves are correct.
27. Check if all control valves are under the
control of the control system.
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Remaining
deficiencies
Deficiencies
requiring prior
correction
Review results or
requirements for
correction

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Table A (Continued)
Safety valve
Select
Irrelevant

Relevant
Remaining
deficiencies
Deficiencies requiring
prior correction
Review results or requirements

for correction
28. Safety valves are within

valid periods of inspection
and have inspection labels.
29. Rated pressures of
safety valves do not exceed
the designed pressures for
vessels, containers, pressure
pipes and equipment.
30. Isolation valves of
safety valves have been
opened completely.
31. Isolation valves have
been locked or sealed.
32. If possible, verify if
isolation valves are really
opened.
Items to be confirmed for

overhauls due to accidents
Select
Irrelevant

Relevant
Remaining
deficiencies
prior correction

for correction
33. Check if the causes of

the accident have been
found.
32. Check if the causes of
the accident have been
eliminated.
35. Check if operation
staffs have learnt the
lessons from the accident.
36. Check if measures to
prevent reoccurrence of the
accident are in place.
Auxiliary materials for

start-up
Select
Irrelevant

Relevant
Remaining
deficiencies
37. Check if auxiliary

materials
meet
the
standards for the process or
equipment.
38. Check if auxiliary
materials
meet
the
requirements
for
the
process and equipment and
are adequate in quantity.
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prior correction

for correction

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Table A (Continued)
Other relevant systems
(power, cooling and
circulating systems)

Select
Irrelevant

Relevant
Remainin
g
deficiencies
Deficiencies
requiring prior
correction
Review results or requirements for

correction
39. Check if relevant systems

meet start-up requirements.
40. Check if power systems
have
passed
pre-startup
insulation tests and seal heads
meet
explosion
proof
requirement.
Other inspection items
Select
Irrelevant
Relevant

Remaining
deficiencies
prior correction

correction
41. Confirm if all operation

and maintenance procedures
meet the requirement.
42. Check if operators have
obtained
operation
procedures for start-up of
relevant equipment, received
training
and
acquired
corresponding qualification
certificates.
43. Exchange opinions on the
inspection with maintenance
staffs and the person in
charge of maintenance and
reach a consensus that all
tasks have been completed.
Overhaul or maintenance work reviewed by:
Date:
Technology reviewed by:

Date:
Safety reviewed by:

Date:
Operation reviewed by:

Date:
Area or Unit Chief:

Date:
Others:
Date:
Brief description of approaches used in equipment/process start-up
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Appendix B PSSR Checklist (applicable to new, modified and expanded

systems and systems subject to changes)
Table B PSSR Checklist
(applicable to new, modified and expanded systems and systems subject to changes)
Production Unit/ Installation/ Equipment
Time of review
Reviewed by
Brief description of the project under review:
Personal safety and health

Select
actions
Deficiencies
Remaining
Irrelevant Relevant
requiring prior
deficiencies
correction
1. Is personal protection equipment (PPE) adequate?

2. Does the PPE provided meet the requirements for
controlling the hazards at site?
3. Is PPE put at an appropriate and easily accessible
place?
4. Is PPE certified to be qualified and within the valid
period?
5. Have noise reduction measures been adopted or
clear warning signs been placed at high noise areas?
Are staffs equipped with earplugs?
6. Is the lighting adequate?
7. Are there walkways or ladders or stairs leading to
platforms at height?
8. Are walkways or working platforms made anti-slip
and equipped with safety protective devices, such as
rails and fences?
9. Are safety measures required for working at
heights in place?
10. Do workplaces have adequate ventilation?
11. Do sight holes, flow directions and meter glasses
meet safety requirements?
12. Have working platforms / scaffolds been cleared?
13. Have all the wastes or replaced materials been
cleared?
14. Have hydraulic test equipment and other
temporary equipment been cleared?
15. Have temporary connection pipes, hoses, power
lines, signs and markings, etc., been cleared?
16. Have unused and unnecessary materials been
cleared?
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Review results or
requirements for
correction

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17. Have any other materials requiring

clearance been cleared?
Table B (Continued)
18. Are there enough signboards or

fences to clearly mark working areas
or dangerous zones?
19. Are exits clearly marked?
20. Has personal exposure to
chemical materials during clearing
and maintenance been minimized?
21. Are storage areas clearly marked?
Are there any clearly written
procedures
governing
the
loading/offloading and use of
compressed gas cylinders?
22. Is there any measure to prevent
people from contact with high/low
temperature and high/low voltage
power supply?
23. Are materials placed in order and
easily accessible?
24. Are vessels, storage tanks and
operation equipment clearly marked?
25. Has equipment out of service
been isolated or marked?
26. Can safety showers and eye wash
equipment work well?
27. Are positive pressure respirators
adequate in number, meeting relevant
standards and in good and reliable
working conditions?
28. Is the connection for nitrogen
system different from that for
instrument air?
29. Are confined spaces at site clearly
marked?
30. Are audio and visual alarms
certified to be qualified, within the
valid period and can function well?
31. Is there a checklist and reaction
matrix or safety instruction for
chemicals within the area?
32. Is entry into production areas
controlled?
33. Are Do Not Touch signs clear
and conspicuous?
34. Are all the MSDSs the latest? Can
they be found at site?
35. Are material hazard training
materials
and
communication
procedures the latest?
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Table B (Continued)
Review
actions
results or
Deficiencies
Remaining
Irrelevant Relevant
requiring prior requirements
deficiencies
for correction
correction
Select
Process and equipment safety
36. Have process and equipment start-up plans been prepared and
approved?
37. Are temporary safety measures in the start-up plan in place?
38. Has equipment been equipped with protective devices as required?
39. Are there latest MSDSs for lubricating oil and sealing liquids?
40. Check if auxiliary materials meet process and equipment
standards.
41. Check if auxiliary materials meet process and equipment
requirements and are adequate in quantity
42. Are the loading capacities for floors, guide rails, triangle derricks
and lifting slings clearly marked?
43. Can equipment be cleaned, isolated and maintained?
44. Are operation steps for key valves specified in the process flow?
45. Can valves be locked according to the lockout/tagout procedure?
46. Are valves easy to access for operation purpose?
47. Are required isolations placed at intersections of pipelines
containing different materials?
48. Are pipelines checked one by one as required?
49. Have pipe sections out of service been isolated or removed?
50. Are sewage discharge and venting points at locations easy to see
and operate?
51. Are sampling points at locations easy to see and operate?
52. Are sampling points enough?
53. Are pipelines properly supported as required?
54. Are cantilever connections supported?
55. Are all pipeline supports in close contact with the pipelines and
bearing even weight?
56. Are pipeline expansion absorption devices and measures in place?
57. Does the use of hoses and flexible connections meet safety
requirements?
58. Have backflow prevention devices (check valves) been installed?
59. Are locations, directions and angles of check valves installed
correctly?
60. Are locations, directions and angles of filters installed correctly?
Are they easy to open and clean?
61. Are temporary connection pipe sections of appropriate length?
62. Have static jumpers and groundings been installed on pipelines as
required?
63. Have cathodic or anodic protections installed for underground
pipelines?
64. Are insulations used for mandatory cathodic protections to prevent
electric current from entering other pipelines and equipment?
15

Management
65. Have items 62, 63 and 64 been tested? Have test records been
filed?
66. Have pressure test liquids, chemical cleaning liquids and neutral
liquids for commissioning in pipelines and equipment been cleaned?
67. Are gaskets fit for the materials and temperatures of the process?
68. Are gaskets fit for the pressure levels of valves and pipelines?
69. Do gaskets and flanges match the connections of equipment?
70. Are flange gaskets placed at correct positions?
71. Check if flanges have any damages.
72. Have air-tightness tests been conducted for flange connections?
73. Check if bolt gaskets are appropriate and complete.
74. Does installation of bolts and nuts meet relevant requirements? Do
they become loose?
75. Do release points for safety valves lead to safe positions? (Posing
no threat to either people or equipment)
76. Are release pipes for safety valves adequately supported and fixed?
Do pipe diameters meet relevant requirements?
77. Have isolation valves of safety valves been opened completely?
78. Have isolation valves of safety valves been locked or sealed?
79. If possible, verify if isolation valves are really opened.
80. Are locking/unlocking valves in process pipelines at correct status
and locked? (To avoid formation of enclosed pipe sections and mixing
of different materials)
81. Do safety valves of direct discharge type have weep holes and rain
hats?
82. Are isolation valves of release valves in unlock state?
83. Are status checklists for isolation valves of release valves the
latest?
84. Do new pressure settings for safety valves meet relevant
requirements and communicated to operation and maintenance staffs?
85. Have vibration abatement devices for pipeline equipment been
installed?
86. Have fix bolts for expansion joints been loosened?
87. Have protective covers and rails for moving/rotating parts been
installed?
88. Have radiation equipment been protected as required?
89. Have lockout/tagout points been locked and tagged?
90. Are serial numbers of equipment and instruments are clear and
easy to read?
91. Are blind plates and spectacle blinds correctly installed, numbered,
tagged and registered?
92. Are discharge points equipped with receiving trays (pools) and
installed with blind plates or screw plugs?
93. Have thermal insulations been completed as designed?
94. Are three-way valves correctly marked?
95. Are pressure and temperature meters and flow indicators installed
at positions easy for reading?
96. Are all measuring instruments and meters certified to be qualified,
16

Revision: 2.0

Management

Revision: 2.0
within the valid period and with correct indications?

97. Have equipment lubrication jobs been completed?
98. Is the process safety management procedure the latest version and
does it cover additional equipment and changes?
Table B (Continued)
Electric safety
Select
Irrelevant

Relevant
Remaining
deficiencies
99. Does electric equipment comply

with the standard for explosion proof
level of the area?
100. Can start and shutdown
switches and electric switch cabinets
be differentiated from their tags?
101. Are there as-built drawings of
electric lines?
102. Are power use permits and
work permits approved?
103. Are fittings for conducting wire
guide tubes sealed?
104. Have power indicator lights
passed tests?
105. Have electric grounding for
power equipment passed tests?
106. Do electric lines meet the
requirements for load and laying?
107. Have insulations for electric
lines passed tests?
108. Have all the required electric
safety devices been provided and
certified to be qualified?
109. Are safety protective devices
for electric equipment installed as
required?
110. Has motor steering been
examined?
111. Have electric interlocks passed
function tests?
112. Have electric insulation and
temperature rise passed tests?
113. Have electric protection relays
and safety devices been installed and
tested?
114. Has staffs be provided training
on lockout / tagout management
procedure?
115. Are lockout/tagout points fixed?
17
Deficiencies
requiring prior
correction

correction

Management

Revision: 2.0
Table B (Continued)
Select
Control System
Irrelevant Relevant
116. Has the fault state of emergency shutdown

(ESD) valves and control valves been confirmed
both at site and in the control room? Are they
matching each other?
117. Have functional tests been conducted for
ESD valves?
118. Has bypass function of the ESD valves been
confirmed to be unblocked?
119. Is the causal relation of the ESD system the
latest?
120. Have loop and functional tests been
conducted for automatic control valves?
121. Are travels and failure positions of all
control valves correct?
122. Are all control valves under the control of
the control system?
123. Have new critical instruments and analysers
been calibrated and verified?
124. Are there as-built drawings for loop and
analyser control logics?
125. Have new critical instruments been covered
by monitoring, maintenance and repair plans?
126. Can automatic valves be isolated for
maintenance purpose?
127. Have pressure, temperature, liquid level and
flow control meters been calibrated and verified?
128. Are system alarm checklists the latest?
129. Is there a procedure for regular test of alarm
interlocking logic?
130. Have alarms and interlocks passed tests?
131. Have alarm and interlock documents been
filed?
132. Is there a procedure for maintenance of
alarm and interlock devices?
133. Have computer failures of the control
instrument system been addressed in both the
operation procedure and emergency response
procedure?
134. Can the computer controlling the ESD
system and the computer controlling the
distributed control system (DCS) for process
operations work independently?
135. Are trigger sensors of the ESD system
independent from the operating control system?
18

Remaining
deficiencies
Deficiencies
requiring prior
correction
Review results or
requirements for correction

Management

Revision: 2.0
Table B (Continued)
Ergonomics
Select
Irrelevant Relevant
actions
Deficiencies
Remaining
requiring prior
deficiencies
correction
136. Are control buttons, switches

and
valves
convenient
for
operation?
(Avoid excessive
stretching or bowing)
137. Are display screens and control
panels easy to see, understand and
operate?
138. Has heavy manual handling
been minimized?
139. Have glare and reflection from
working surfaces and screens been
removed?
140. Are work spaces for operators
and maintenance staffs big enough
and comfortable? i.e. big enough for
them to stand up, turn around and
bend 90 degrees with one foot on
the ground and both hands holding
one ankle.
141. Are emergency alarms resistant
from interference by process
operation noise? Can staffs hear
emergency alarm at any location?
142. Have repetitive forced actions
(e.g. rhythmic movements following
machines) been minimized?
143. Have manual handling of toxic
and hazardous materials been
minimized?
144. Has the time for staffs to wear
PPE, such as chemical protective
clothing and positive pressure
respirators, been minimized?
19
Review results or requirements for correction

Management

Revision: 2.0
Table B (Continued)
Fire control
Select
Irrelevant Relevant
145. Have fire walls and fire doors been

constructed and installed?
146. Do fireproof materials meet relevant
requirements?
147. Are fire extinguishers equipped according to
required quantity, types and locations?
148. Are fire extinguishers put in right places and
numbered?
149. Have registration and inspection records for
new fire extinguishers been established as
required?
150. Do fire control facilities meet the
requirements for quantity, capacity and locations in
the design? (such as water sprinkling systems,
automatic fire extinguishing devices, fire hydrants,
etc.)
151. Have fireproof layers been installed below
cable bridges as necessary? Have water sprinklers
been installed above cable bridges as necessary?
152. Have water sprinkling, fire water and
automatic fire extinguishing systems passed system
function tests?
153. Are pipelines for water sprinkling, fire water
and automatic fire extinguishing systems
adequately supported?
154. Are drainage valves installed for potential
water accumulation sections in water sprinkling,
fire water and automatic fire extinguishing
systems?
155. Are fire control system diagrams the latest?
156. Are water sprinklers facing the correct
direction?
157. Do flammable gas monitoring devices
installed meet the requirements for quantity,
location and height? Have they been verified to be
qualified?
158. Does storage of flammable liquids meet fire
control requirements?
159. Does fire engine access meet the requirements
in the original design?
160. Is fire engine access unblocked?
161. Are there dedicated or part-time fire brigades?
Is there a regular fire drill plan?
162. Have fire fighting systems been accepted by
the fire control authority?
20

Remaining
deficiencies
Deficiencies
requiring prior
correction
Review results or
requirements for correction

Management

Revision: 2.0
Table B (Continued)
Process safety information
Select
Irrelevant Relevant

Remaining
deficiencies
Deficiencies
requiring prior
correction

correction
163. Is there an established procedure for

process safety information management?
164. Are the MSDSs of all materials
ready, updated and accessible?
165. Have chemical reaction matrices or
specifications been developed or
updated?
166. Are management standards for toxic
and hazardous materials ready?
167. Have as-built drawings of processes
and equipment been filed and updated?
168. Have technical materials of
processes and equipment been filed and
updated?
Process and mechanical changes
Select
Irrelevant Relevant

Remaining
deficiencies
169. Did all changes follow the

procedure for process and mechanical
changes? Have they been checked?
170. Have all technical items related to
process and mechanical changes been
checked?
171. Have all the people responsible for
the project signed the change application
form for confirmation?
172. Has the procedure for process
change management been applied to all
changes?
173. Have all the items of change related
to operation been completed?
174. Have approval processes required
for operation and maintenance been
implemented for the change?
175. Are documents required by the
change the latest version?
176. Are trainings required by the change
completed?
177. Have temporary protective devices
used in the process of change been
removed?
21
Deficiencies
requiring prior
correction

correction

Management

Revision: 2.0
Table B (Continued)
Process hazard analysis
178. Have process hazard analyses been conducted
for new and modified systems?
179. If yes, have recommendations proposed in
process hazard analysis reports been implemented?
180. Has the process safety coordinator filed all
recommendations?
181. If lack of process hazard analyses, have
recommendations based on pre-startup hazard and
environment aspect identification been implemented?
182. Have recommendations from process risk
analyses required by changes been implemented?
183. Has all process safety information related to
changes been updated? Including operation manuals,
alarm parameters, additional safety equipment,
deviations, set values, upper and lower safety limits
in normal operation, etc.
184. Have people directly responsible for processes
and equipment got all the process safety information
they need?
185. Has the process risk analysis report been
completed?
186. Does the process risk analysis report reflect
changes in the construction process?

Select
Deficiencies
Remaining
Irrelevant Relevant
requiring prior
deficiencies
correction
Review results or
requirements for
correction
Incident investigation
Select
Remaining
Irrelevant Relevant
deficiencies
187. Is this new or modified project required by the

analysis results of previous accidents?
188. If yes, have all the recommendations been
implemented?
189. If yes, have all the recommendations been
documented and filed by the process safety
coordinator?
190. Have the accident investigation report and
recommendations been communicated to relevant
operators?
191. Have the contents of the accident investigation
report and recommendations been communicated to
equipment maintenance staffs?
192. Have maintenance related recommendations in
the accident investigation report been implemented?
193. Have recommendations in accident analysis
reports of similar processes or equipment been
implemented on the processes and equipment under
review?
22
Deficiencies
requiring prior
correction
Review results or
requirements for
correction

Management

Revision: 2.0
Table B (Continued)
Mechanical integrity
Select
actions
Irrelevant Relevant
Deficiencies
Remaining
requiring prior
deficiencies
correction
194. Is there a repair and maintenance procedure for all

equipment?
195. Has the quality and quantity control procedure for
maintenance materials and spare parts been developed
and approved?
196. Have critical equipment maintenance tracking
records been established?
197. Have the inspections and testing of the following
equipment been completed? Have the records been
filed? Has regular testing during normal operation been
included in the maintenance plan?
(1) Pressure vessels
(2) Pressure release and venting devices
(3) Control equipment, control logic and alarms
(4) Emergency response equipment, including
emergency shutdown and isolation devices or systems
(5) Firefighting facilities
(6) Pipelines for transporting toxic and poisonous
materials (including valves, restrictor valves, expansion
joints, hoses, etc.)
(7) High speed turbines, centrifugal separators and
other high speed rotary devices
(8) Material intake connectors of key process pipelines
(9) Electric and static groundings and static jumpers
(10) Emergency alarm system
(11) Monitoring instruments and sensors (for pressure,
temperature, flow, etc.)
(12) Pumps
(13) Hoisting and lifting equipment
(14) Ventilation systems
198. Have statutory inspections and tests been certified
by relevant regulatory authorities (or third parties) (e.g.
for pressure vessels, hoisting and lifting equipment,
firefighting equipment, etc.)?
199. Have all commissioning and testing preparations
been completed?
(1) Hydraulic tests
(2) Air tightness tests
(3) Chemical cleaning, passivation, etc.
200. Can spare parts of process pipelines and
equipment meet the minimum storage requirement?
201. Has an equipment lubrication plan been developed
based on equipment lubrication requirements?
23

for correction

Management

Revision: 2.0
Table B (Continued)
Select
Quality assurance
actions
Deficiencies
Remaining
Irrelevant Relevant
requiring prior
deficiencies
correction
202. Have equipment provided by suppliers been verified to

meet the parameters in design specifications?
203. Has installation of critical equipment been confirmed to
meet the parameters in design specifications?
204. Has installation of critical equipment been confirmed to
meet the requirements in the equipment technical
specifications from the supplier?
205. Does the equipment quality inspection report, including
equipment manufacturing, assembling and installation,
comply with the quality assurance management plan of the
project? Has the report been filed together with design
documents?
206. All members of the JSSR team have conducted site
inspections and reached a consensus or signed for
confirmation that:
(1) Installation of all equipment meets the requirements in
design documents.
(2) Installation of all process pipelines is consistent with the
drawings.
(3) Installation of all gaskets meets the requirements in
design documents.
(4) Support to and fixation of all pipelines meet design
requirements and are adequate.
207. The JSSR team has confirmed at site that the use of all
low temperature materials (including containers, pipelines,
gaskets, flange bolts, etc.) meet the requirements in design
documents.
Review results or
requirements for
correction

Select
Operating procedures
Irrelevant Relevant
208. Have safe work specifications (safety management

standards for high risky operations) been formulated, updated
and approved?
209. Have all safety related requirements during operations
(high risky job performance) been included in operating
procedures?
210. Are there any new safe operation requirements to be
added to operation procedures after changes to equipment?
211. Is it necessary to test updated operation procedures with
water, chemical solutions or other safe neutral solvents?
212. If necessary, is there any operation procedure to provide
assurance?
213. If the test proves that the procedure or the equipment
fails to meet the requirements, will the operation procedure or
deficiencies of the equipment be corrected?
214. Have operation procedures for processes and equipment
24
actions
Review results or
Deficiencies requirements for
Remaining
requiring prior correction
deficiencies
correction

Management
been formulated, updated and approved?

Revision: 2.0
Table B (Continued)
Training / Competence Assessment
Select
Irrelevant Relevant

Remaining
deficiencies
215. Have operation staffs (including DCS operators)

received training on skills required by their jobs? Are
their skills?
216. Have maintenance staffs (including mechanical,
instrument and electric maintenance staffs) received
training on skills required by their jobs? Are their
skills verified?
217. Have managers/supervisor received training on
skills required by their jobs?
218. Have special operation staffs obtained work
certificates required by the special operation they
perform? Are their certificates valid?
Deficiencies
requiring prior
correction
Review results or
requirements for
correction
Contractors
Select
Irrelevant Relevant
219. Are training materials for contractor staffs

ready?
220. Have contractor staffs received training on skills
required by their jobs?
221. If the project involves changes to a system, have
training materials for contractor staffs been upgraded
or updated?
222. Have management controls for access to
production areas and operation performance by
contractor staffs been finalized and implemented?

Remaining
deficiencies
Deficiencies
requiring prior
correction
Review results or
requirements for
correction
Management of personnel change
Select
Irrelevant Relevant
223. Have all staffs involved in job changes (change

of job, promotion, new employee, etc.) been trained,
assessed and confirmed for competence following the
procedure for personnel change management?
224. Do existing staffs meet the minimum experience
requirements for safe operation of the processes and
equipment?
225. Are PSSR team members competent in
conducing PSSRs?
25

Deficiencies
Remaining
requiring prior
deficiencies
correction
Review results or
requirements for
correction

Management

Revision: 2.0
Table B.1 (Continued)

Emergency response
Select
Irrelevant Relevant
Remaining Deficiencies requiring

deficiencies
prior correction
226. Have emergency shutdown buttons passed

functional tests?
227. Are measures in response to trigger of
emergency shutdown systems presented in the
emergency response plan?
228. Public utilities, such as water and electricity
facilities, to be used in emergency responses, shall be
listed in the emergency response plan. If the
availability of such utilities cannot be guaranteed, are
there alternatives measures?
229. Have staffs received training on prevention
from harm by release of toxic and hazardous
materials? Are they verified to be competent?
230. Have staffs received training on use of
emergency shower and eyewash equipment? Are
they verified to be competent?
231. Have staffs received training on use of positive
pressure respirators? Are they verified to be
competent?
232. Are emergency alarm devices provided?
233. Is emergency alarm devices reliable and easy to
use?
234. Can emergency lighting systems work properly?
235. Are emergency escape routes and muster points
clearly marked and known by all staffs?
236. Are escape routes unblocked and safe?
237. Are escape facilities (such as escape slide
systems, ropes, etc.) prepared?
238. Are escape facilities reliable and easy to use?
239. Can the emergency response plan meet the
requirements from process hazard analyses?
240. Have emergency response teams conducted
relevant drills?
241. Are contacts for emergency rescue resources
confirmed?
242. Are there backup contacts for emergency
responses and can they meet safety requirements?
243. Are emergency rescue facilities equipped
according to required quantity, type and location?
244. Have emergency rescue staffs received required
training? Are they verified to be competent?
245. Are there adequate first aiders?
246. Have trainings on first aid procedures and
methods been conducted and training results been
verified?
247. Are first aid kits adequate?
248. Have emergency response
communicated to all relevant parties?
plans
been
26
Review results or
requirements for
correction

Management

Revision: 2.0
Table B (Continued)
Environmental protection
Select
Irrelevant
Relevant
Remaining
deficiencies
Deficiencies
requiring prior
correction

correction
249. Are characteristic descriptions of

wastes documented and accessible?
250. Is there any information on
environmental impacts of process
materials?
251. Can discharge/emission control
equipment work properly?
252. Are water drainages, sewage
discharge facilities and cofferdams
adequate to contain spills and polluted
rainwater?
253. Can sewage pipeline drawings
reflect actual changes?
254. Are isolating valves of water
drainage closed?
255.
Have
waste
(including
commissioning wastes and defective
products) treatment practices been
determined?
256. Have environmental incident
response procedures and resources
(personnel, equipment, materials, etc.)
been confirmed?
257. Can environmental laws, regulations
and standards applicable in the host
country and the environmental policies
and procedures of the Company been
complied with?
PSSR checklists
Select
Irrelevant

Relevant
258. Does the checklist cover all safety

inspection items required by the safe
start-up and operation of the processes
and equipment under review?
259. If not, the PSSR checklist should be
discussed and improved by the PSSR
team.
27
Remaining
deficiencies
Deficiencies
requiring prior
correction

correction

Management

Revision: 2.0
Appendix C PSSR Checklist (applicable to safety review before spud-in)

Table C PSSR Checklist
(applicable to safety review before spud-in)
Date
Well No.
Rig No.
Rig Contractor
Inspection team
LOCATION
SN
Item description
All equipment are spotted properly as per the rig lay out
& required safe distances.
Location entrance & exit clearly identified with signs.
All hazard signs are posted on location.
Proper trough to be provided behind brine/mud tanks for
draining waste to waste pit.
Hazardous and non- hazardous waste bins are provided
Adequate size of waste pit with proper lining has been
provided.
Ensure Confined Space Permit is completed and
implemented prior to all cellar entries. Cellar area
should be monitored for explosive gases/LEL, H2S &
O2 levels with a Sniffer.
Clean cellar, weld 4 dump valves on 42 conductor &
check cellar jet pump is working okay.
Ensure previous location is cleaned & leveled.
2
3
4
5
6
7
8
9
AIR WINCHES
SN
2
3
Y/N
Item description
Y/N
Check condition of and function where relevant:

a) Mountings
b) Marking plates indicating up and down
c) Marking plates indicating the SWL
d) Wire line drum guards.
e) Winch operating controls
f) Winch safety controls
Ensure man riding tuggers are clearly designated.
Check when mounting bolts last inspected or replaced.
28

correction

for correction

Management
4
SN
Item description
1
2
Check all functions are clearly labeled.

Check when the overhead BOP cranes were last
inspected and that they are currently certified.
Ensure that cranes are free from obstruction over their
full range of movement in the cellar pit area
Check operation of all visual and audio warning devices
fitted to BOP cranes.
BULK MUD AND CEMENT SYSTEM

SN
Item description
1
2
3
Make sure all the lines are correctly labeled.

Make sure all silos are clean and dry.
Pressure test all valves and lines up to the rated working
pressure.
Check certification of pressure relief valves. Ensure that
valves vent into areas clear of personnel.
Function test the vent lines, purge lines, supply and
discharge lines.
Check operation of bulk air compressors and driers
Check condition of and function bulk mud hoppers and
mixers.
4
5
6
7
CRANES & FORKLIFT

SN
Item description
1
2
Check all crane functions are clearly labeled.

Check PM records to ensure that there are no
outstanding maintenance items and crane and associated
equipment are fully certified.
Operate crane and check that all functions and safety
devices are operational.
Check operation of all visual and audio warning devices
fitted to crane and forklift.
Check general condition of crane cabins, walkways and
access ladders and stairs.
Check cranes and refueling systems for leaks.
3
4
5
6
Revision: 2.0
Check air silencers.
BOP HANDLING
DERRICK MAST
SN
Item description
Check that the ladders and resting platforms are

properly fastened and in accordance with the
regulations.
29
Y/N

for correction
Y/N

for correction
Y/N

for correction
Y/N

for correction

Management
2
3
4
5
6
7
8
9
10
11
SN
Item description
1
2
Drill Pipe last inspection.

Visually examine all rig drill pipe, drill pipe pup
joints and heavyweight drill pipe. Check general
condition, correct grade and weight and date of
last inspection. Check all pipes specified by
contract are at the rig site.
Drill Collars:
Visually examine all drill collars and pup collars.
Checks as detailed above for drill pipe.
Check to ensure that all other downhole tools (e.g.
crossovers, bit subs etc) listed on the rig inventory
are at the rig site and have been inspected as per
contract.
Check inventory and condition of drill pipe float
valves and spares.
BHA completely pick up & rack in derrick before
spud
BHA & drill pipes inspected. Submit copy of
inspection report & BHA tally as listed on the rig
inventory are at the rig site and have been
inspected as per contract.
5
6
7
Revision: 2.0
Check operation and condition of climbing aids and

derrickman's escape system.
Check that all tools and equipment are safely stored or
tied off.
Rotary table centering with respect to mast + top drive
& rotary center & cellar center
With cellar conductor pipe
Check that lighting is adequate.
Check equipment installed in the mast e.g. taggers,
communications.
Function test and check safe installation.
Ensure that all shackles, blocks, slings etc. installed in
the mast are correctly color coded and included in the
lifting register. All shackle pins must be "wired".
Check daily and weekly derrick checklists are in place
and completed as required.
Check that a "derrick management" system is in place
regarding dropped object avoidance.
DOWNHOLE DRILLING EQUIPMENT
DRAW WORKS
SN
Item description
1
2
Function test all controls.

Run the travelling block up and down and check
operation of:
30
Y/N

correction
Y/N

correction

Management
3
4
5
SN
Item description
Check pressure gauges for condition and

correlation with other gauges
a) Mud pressure
b) Air pressure
c) Water cooling
d) Oil pressure (draw-works)
Check operation of all drilling instrumentation and
whenever possible correlate readings e.g. check pit
volume totalizer when leak testing mud pits.
a) Top drive and rotary RPMs
b) Flo-Show
c) Pit volume totalizer
d) Tong torque indicator
e) Top drive and rotary torque
f) Drilling recorder
g) Electro-flow system
h) Electrical and mechanical trip tank level
i) Weight indicator
Check that all TV systems are working.
Check that all alarms are working correctly.
Check operation of communications systems
including the drillers to the derrickman.
All driller instrumentation, SDI- gelograph in
working condition & calibrated, all SDI panels in
TP, CO-MAN & SR-CO-MAN connected &
working.
Check that all switches, buttons, etc. are labeled
and are in good condition.
Check that all electrical switching corresponds to
the panel description. (test run all machinery
under every possible assignment).
Check that all electrical equipment (e.g. switches,
motors, junction boxes, etc.) are explosion proof or
purged.
4
5
6
7
8
9
10
Revision: 2.0
a) Crown-o-matic
b) Crown block saver
c) Elmagco braking system
d) Emergency back-up system
Check maintenance records with particular
reference to break band replacement, NDT of
critical components.
Draw works cooling system OK.
Check system for leaks.
DRILLERS CONSOLE & DOGHOUSE
Y/N
31

correction

Management
11
12
1
2
3
Item description
1
2
3
4
Y/N

correction
Y/N

correction
Physically check inventory of all fishing tools to

confirm that it contains all tools listed in the
contract.
Ensure that tools and grapples are available to
catch all of the Contractor's drill string and
crossovers.
Ensure that all fishing tools have been redressed
and inspected since last usage.
HYDRAULIC POWER UNITS

SN
Revision: 2.0
Check that there are no obstructions and that

walkways and escape routes are clear.
Check general condition of console including
doors and windows.
FISHING TOOLS
SN
Item description
Note: These tests refer to the unit(s) needed to

power equipment such as Iron roughneck, facilities
on top drive, casing tongs & other hydraulic
equipment
Operation of hydraulic power units will be
checked when testing the above equipment.
Check operating and emergency shutdown
controls.
Check for leaks, and note general condition of
equipment.
Check that unit's zone rating is correct for area in
which the unit is located.
LOW PRESSURE PIPING & VALVES

SN
Item description
Check all lines are clearly labeled to indicate contents.
Circulate through all lines (e.g. transfer, treatment and

mixing) with water and check for leakage or plugging.
MUD AGITATORS
SN
Item description
1
2
3
Start all agitators before filling up the tanks.

All mud agitators in working condition in all tanks.
Check for noise and vibration.
Check general condition and security of agitators,
mountings and paddles.
Check system in place for locking out motors.
4
5
32
Y/N

for correction
Y/N

for correction

Management
MUD DEGASSER, DESNADER, DESILTER

SN
Item description
Check PM's on motors, drive belts, etc., for

abnormalities.
Visually check equipment, and note general condition.
2
3
SN
Item description
Check general condition of separator and associated

lines and valves.
Check and note date of last pipe thickness inspection.
Revision: 2.0
Y/N

for correction
Y/N

for correction
Function test equipment.
MUD GAS SEPARATOR
2
3
Flush through system with water.

Check condition of all instrumentation located on the
separator or at a remote location viz., in the driller's
console.
MUD MIXING, TRANSFER AND CHARGING PUMPS

SN
Item description
Run each pump separately for fifteen minutes with

water and check for leaks and operating pressure.
Run pumps against closed valves and check operating
pressure.
Check inventory of pump spares.
2
3
MUD PITS
SN
Item description
Y/N

for correction
Y/N

for correction
Check general condition of:

a) Pits.
2
3
4
b) Gratings and access ladders.

c) Isolating, equalizing and dump valves.
Ensure pits are clearly labeled.
Fill each pit with water and check for leaks between
adjacent pits and through isolating, dump and equalizing
valves.
Pump through and check operation of all mud guns.
MUD PUMPS MANIFOLDS AND HIGH PRESSURE PIPING

SN
Item description
Y/N
Check that all lines and valves are correctly labeled and
all valves have operating handles.
33

for correction

Management
2
3
4
5
6
7
8
9
SN
Item description
Check condition of and function test the main power

generation systems.
Check condition of and function test the emergency
generator.
Function test all air compressors including the cold start
compressor.
Check that all required safety devices are installed,
operational and certified.
Ensure that all air receivers and safety relief valves are
certified.
Check engines cooling system.
Fuel supply system should be leak proof. All engines
must be in running condition.
Check condition of and function test sewage treatment
plant.
3
4
5
6
7
8
PLANNED MAINTENANCE SYSTEM

SN
Item description
Ensure that the PM system complies with the Rig's

Verification Scheme for safety critical components
Carry out random checks on the PM system to ensure
that the work listed on the PM Task Forms has actually
been completed
Ensure that no critical safety or operational maintenance
tasks are still outstanding on the PM system.
2
3
Revision: 2.0
Flush all lines with water and fill up manifold.

Pressure test pump manifold to rated manifold working
pressure.
Check pressure gauges and recorders, calibrate or
replace if necessary.
Whenever possible cross reference all gauges reading
the same pressure source.
Circulating system tested with all mud pumps.
Ensure that there are no threaded high pressure
connections on the manifold.
Mud pump relief lines fixed. Check mud pumps fluid
end & dressed with liners for spudding.
Note date of last pipe thickness check.
POWER AND SERVICES
RIG FLOOR STAND PIPE MANIFOLD

SN
Item description
Check that all lines and valves are correctly labeled and
all valves have hand wheels.
34
Y/N

for correction
Y/N

for correction
Y/N

for correction

Management
2
3
4
5
6
7
8
9
SN
6
7
Item description
1
2
3
4
5
6
Y/N

for correction
Y/N

for correction
Y/N

for correction
Function test the rotary table.

Check RPM counter.
Check torque gauge.
Check for abnormal noise or vibration in all gears.
Make sure all ratios (low and high speeds) can be easily
engaged.
Check for oil leakage
Check condition of rotary bushings and ensure that
dimensional checks have been carried out under the PM
system.
SHALE SHAKERS
SN
Revision: 2.0
Flush all lines with water and fill up manifold.

Pressure test manifold to rated manifold working
pressure.
Rig up EZY torque, cat heads, iron rough neck & tested.
Rig up survey wire line unit & sheaves. Check geograph
is working.
Check all wire ropes-drill-line, winch line, tong-line,
etc.
Check pressure gauges and recorders, calibrate or
replace if necessary.
Whenever possible cross reference all gauges reading
the same pressure source.
Note date of last pipe thickness check.
ROTARY TABLE AND TRANSMISSION

1
2
3
4
5
Item description
Check the general condition of each shaker.

Run each shaker and check for:
a) Abnormal noise and vibration.
b) Oil leakage.
Check inventory of spare parts, e.g. motors.
Check shaker screens on all shakers and ensure all
shakers in working condition.
Check inventory of shaker screens and ensure that it is
suitable for the proposed drilling programme.
Check condition of valves on the header system and the
discharge chutes.
STABBING BOARD
SN
Item description
Check for safe installation of the casing stabbing board.
35

Management
2
3
4
5
SN
1
2
3
4
5
6
Item description
1
2
3

for correction
Y/N

for correction
Y/N

for correction
Check when new wash pipe was last installed.

Check for abnormal noise or vibration.
The above will be tested to rated working pressure at the
same time as the top drive.
Item description
Run the top drive up and down and check:

a) Guide rails
b) Fouling of cables and hoses with derrick and fittings
During test, check:
a) Functions properly labeled on control panel
b) All indicators / gauges working
c) All electric devices explosion proof
d) Oil leakage
e) Air leakage
f) Indicator lights operational
Install the IBOP and saver sub using the pipe handler.
Function test the remote operated IBOP (Kelly cock).
Pressure test the IBOP(S) and top drive mud circulation
components to rated working pressure.
Using Rotary tong with tong pull line check calibration
of the torque indicator for make-up and break-out
torque.
TRIP TANK AND FILL UP PUMP

SN
Y/N
Check for oil leakage
TOP DRIVE
SN
Revision: 2.0
Check it is securely mounted in derrick.

Check air supply, stabbing board controls, and backup
safety systems.
Function stabbing board for full movement up, down,
extend and retract.
Check stabbing board is not fouled by any other items
of rig equipment, tugger lines etc.
Check stabbing board is correctly certified as a lifting
appliance.
SWIVEL
1
2
3
4
Item description
Flush system through with water.

Rig up hole fill up line & line to trip tank.
Check manual and electronic trip tank level measuring
36

Management
1
2
3
4
5
6
7
8
9
10
11
Item description
1
2
3
4
5
6
7
8
9
10
11
12
Y/N

for correction
Y/N

for correction
All ladders fixed & hand rails provided.

All crew available for all shifts as per contract.
Mud pits and charts calibration by geoloyg/datalog. Kill
sheet is prepared
Mud preparation as required volume and density.
Prepare HI-VIS mud 90+ for sweeps.
Rig up recycle pump from waste pit to mud tanks.
Check flow-line /all lines are clear of all cutting & mudcake.
Install water line to water tanks from water wells & fill
all tanks.
Rig up suitable lighting around tig, cat walk &
cementing silos.
All cutting troughs & overflow pipes to be put from
tanks to waste pits.
Check availability of proper X-over safety valves on rig
floor.
HEALTH, SAFETY & ENVIRONMENT

SN
Revision: 2.0
systems and check correlation between the two systems.

Ensure that the mechanical level measuring system can
be clearly seen from the driller's console.
ADDITIONAL CHECKS
SN
Item description
Function test all detection and alarm systems including:

Fire / H2S / Gas / Smoke detectors / Fire alarms and
emergency alarms.
Check condition of firefighting equipment and check
PM system to ensure that all equipment is fully certified
and maintained. Function test fire water pump.
Windsocks condition to be checked, if worn out to be
replaced.
Inform HSE Dept., Fire Station of new location.
Ensure Oil spill kit is in place.
Fire extinguishers placed in designated places.
Inspection date labeled on extinguishers.
MSDS for all chemicals in place & personnel aware of
the hazards.
Chemical storage organized, hazard signage placed.
Smoking zone identified.
Vehicle parking area identified.
HSE induction & H2S training is in place.
Check breathing apparatus kept on derrick floor &
should be ready for use.
37

Management
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Hazardous zones classified.

H2S & other hazardous sign boards placed.
Check condition of safety belts, free fall device etc.
Eye wash facility on rig floor & mud tanks hooked up
function test same.
Hold H2S & BOP drill to see crew readiness.
Two mustering points clearly marked on the location.
Anchor all high pressure lines.
Ensure First Aid Kit & stretcher is available.
Required PTW is being used.
Communication system operational.
Log Book available and properly entered.
Personnel equipped with safety glasses on rig floor.
Aviation light operational
All rig signs leading to the rig from the main road are
posted.
Ensure drip pans during filling / refilling of fuels.
Ensure all hand rails, steps, stair casing in right order.
Check any slip/trip hazards.
All rotating equipment guarded.
Ambulance with basic trauma care facilities ready.
Rig is equipped with clinic with required facilities &
manned by qualified doctor / licensed medic, nurse.
Pre-spud meeting held.
Site Specific Emergency Response Plan is in place &
exercise prior to spud planned and conducted.
Risks associated with the simultaneous operations in
and around the location are assessed and communicated
to the concerned personnel.
38

Revision: 2.0

Management

Revision: 2.0
Appendix D PSSR Checklist (applicable to safety review before penetrating

into oil and gas formations)
Table D PSSR Checklist
(applicable to safety review before penetrating into oil and gas formations)
Important Notes: The checklist is based on the national standards or petroleum industry standards of the Peoples
Republic of China, which should by no means substitute for, supersede or limit the requirements under the legislation and
standards applicable in the host country. In case of any discrepancy between them, the more strict requirements shall
prevail.
Date
Well No.
Rig No.
Rig Contractor
Inspection team
Items for review

1.
2.
Management
documents
and records
3.
4.
5.
6.
7.
8.
9.
Basic
requirements
Item Description
A complete system of management documents are in place,
including a work permit system which is strictly followed.
Blowout, H2S and explosion response plans are in place,
emergency drills have been conducted regularly and records are
made.
Well control devices meet the requirements in the original design,
and well control measures specific to critical wells, complicated
wells and special wells have been implemented.
Well control equipment are regularly inspected and maintained.
Staffs wear proper PPE as required, hold valid well control
certificates and strictly observe safety procedures, rules and
specifications.
Protective equipment, including H2S monitoring devices and
positive pressure type respirators, are regularly inspected and
calibrated, adequate to meet demands and remain intact and
operational.
Production installations and electric equipment have proper
grounding.
No naked fire is used at the site. Diesel engines are equipped with
flame traps. Electric equipment is explosion proof. Fire control
equipment are adequately equipped and in valid period.
The safety distance between the wellhead and duty room,
warehouse, testing and logging room, geology room, boiler room,
39
Review results
or requirements
for correction

Management
10.
BOP and
casing head
11.
12.
13.
14.
Choke
manifolds,
kill
manifolds,
blowout
preventing
lines and
relief lines
15.
16.
BOP control
system
17.
18.
19.
Liquid level
monitoring
and other
devices

Revision: 2.0
oil tank, power generator, water tank, power distribution room,

remote control console and camp meet relevant requirements.
The blowout preventer has complete connection bolts and is
secured; fluid lines are properly sealed; manual locking rods are
intact and the end at hand wheel is supported firmly; the direction
for On and Off and the number of turns for fully open are labelled;
working platforms are easy for operation; thermal protection is
used on the base of the drilling rig in winter seasons.
Blowout preventing lines are connected by threads and standard
flanges, and on site welding is forbidden. Pipes longer than 7m are
firmly secured. Anti-freezing measures are taken in winter seasons.
The pressure level of casing head is consistent with that of blowout
preventer.
Mud guards are correctly installed. BOP stack, spools and gate
valves are clean and clear of mud.
Choke manifolds, kill manifolds and relief lines are correctly
connected, have flexible switches and in correct operational state.
Pressure gauges are inspected regularly. Anti-freezing measures are
taken in winter seasons.
At every 10 - 15m, cornering positions, and outlets, relief lines
shall be supported and fixed by cement foundations with anchor
bolts or ground anchors, or forecast foundations. Hanging portions
shall be supported firmly.
Outlets of relief lines are fixed by double cement foundations.
Lines laying at vehicle crossings are protected. Safe ignition means
are available for main relief lines.
The power for remote control console is directly from the main
power room or power distribution room through a dedicated power
line and controlled by an independents switch. Pressure of the
power accumulator, annular BOP and manifold meet the relevant
requirements.
Upper and lower kelly cocks are flexible and easy to use; blowout
preventer column, cross-over joint and check valve of drill tool are
equipped; their rated working pressure is no less than that of BOP.
Inlet and outlet lines and exhaust line of the liquid-gas separator are
connected by flanges and firmly secured. Exhaust line is 50m away
from the well site and has reliable ignition devices.
Inventory of drilling fluid weighting materials meets the design
requirements for both quantity and performance. The drilling fluid
weighting unit works properly and the weighting material feed
hopper is unblocked.
40

Management

Revision: 2.0
Appendix E PSSR Report (sample)

Project
Area
Installation/process covered
Process safety information covered
Standard
operating
procedure
reviewed
Codes and standards upon which
the covered process design and
operations were based
Date of the report

Serial No. of equipment
The PSSR team has completed document review and site inspections against the prepared PSSR checklists
and verified that all the deficiencies listed in the report that require prior correction have been corrected up to
the standards.
Reviewed by (Area or Unit Chief)
Date
PSSR Team Composition:
Discipline
Technology
Equipment
Operation
Maintenance
HSE
Electrical
Instrument
Others
Name
Position
Signature
PSSR Team Leader:
Date:
Deficiencies requiring prior correction:

Deficiencies
Requiring Prior
Correction
Date
Responsible
Person(s)
Deadline for
Correction
Completion
Recommendations for
Corrective Measures
Confirmation
of Correction
Completion
Actual
Completion
Date
The report can only be signed for approval after all the deficiencies requiring prior correction have
been corrected.
I have reviewed and verified together with the PSSR team
that all the deficiencies requiring prior correction have been
corrected and all the remaining deficiencies have got monitoring
measures and correction plans and the system can be started
safely.
Approved by (Area or
Unit Chief):
Remaining deficiencies:
Remaining
Deficiencies
Responsible
Person(s)
Deadline for
Correction
Completion
Recommendations for
Corrective Measures
Date:
Confirmation
of Correction
Completion
Actual
Completion
Date
The report has been distributed to the following people:

No.
Name
Organization
Position
41
Discipline
Notes

HSE - 5.7 Procedure For Pre-Startup Safety Review Management

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CNPC International

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

1. Objectives, Scope and Application

2.1 CNPC Corporate Standards

3. Terms and Definitions

3.1 Pre-Startup Safety Review (PSSR)

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

5.1 Basic Requirements

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

PSSR Team Leader

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

plan meeting. The main contents of the meeting are as follows:

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

6. Audit, Renewal, Deviation and Training and Communication

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

Appendix A PSSR Checklist (applicable to system overhaul and maintenance

Production Unit / Equipment

The whole category is not applicable

Remove all unnecessary materials used in

Deficiencies requiring actions

1. Operating platforms / scaffolds

Fire fighting devices and safety facilities

Deficiencies requiring actions

7. Inspect or test fire fighting devices and

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

Check process pipelines and equipment

1.3 Check the shutdown process record of

Deficiencies requiring actions

17. Check the blind plate checklist and

Deficiencies requiring actions

18. Check the tightness of all bolts.

Deficiencies requiring actions

22. Does replacement or adjustment of

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5

Deficiencies requiring actions

Review results or requirements

28. Safety valves are within

Items to be confirmed for

Deficiencies requiring actions

Review results or requirements

33. Check if the causes of

Auxiliary materials for

Deficiencies requiring actions

37. Check if auxiliary

Review results or requirements

Doc. Title: Procedure for Pre-startup Safety Review

Doc. No.: CNPCI Corp HSE 6.5