What is the Pre Startup Safety Review or PSSR?
The PSSR is a safety review conducted prior to startup (commissioning) of a new or modified processing/manufacturing plant or facility to ensure that installations meet the original design or operating intent, to catch and re-assess any potential hazard due to changes during the detailed engineering and construction phase of a project. In other words, it ensures the “Ready for Start-up” status of process facility/units.
A Pre Startup Safety Review covers not only equipment, but also procedures and training.
Pre Startup Safety Review procedure/guideline is normally prepared as part of Pre-commissioning/ commissioning documentation.
What is purpose of the Pre Startup Safety Review?
- To ensure that installation meets the original design and operating intent of process plant/facility
- To ensure safety, operating, maintenance and emergency procedures are in place and adequate
- To ensure appropriate safety reviews during engineering phase (HAZOP study, model review etc.) have been carried out and all action items have been completed
- To ensure any site modifications during construction phase have been properly controlled and noted
- To ensure training of each employee involved in the operating process is completed
- In addition, the pre startup safety review plays an important role in large projects as it may give plant operators the authority to refuse or accept responsibility for a plant or equipment that they judge to be unsafe through the PSSR.
The main activities in a PSSR of a project
Following activities are carried out in a PSSR with coordination between Contractor and Owner of the plant / facilities:
- Coordinate PSSR participation from knowledgeable Contractor and Owner personnel
- Conduct Technical and HSE reviews of documentation and on site
- Verify all construction and equipment is in accordance with safety, environmental and health regulation and standards.
- Complete all corrective action items raised in the PSSR
- Complete Post- Start-up corrective action items
- Representative of the Project Owner sign the PSSR checklists for approval of commissioning/start-up of the plant
- Documentation of PSSR
Pre Startup Safety Review (PSSR) Practices
PSSR is conducted by a team, lead by a Leader. The leader is normally a representative of operation group because they are the ultimate customer of the facility. A PSSR normally consists of 3 steps:
1. Follow-up HAZOP Review: includes the following activities:
- Investigation on the follow-up action items provided by project on recommendations from previous HAZOP study
- Systematic review of all changes to the design since the previous HAZOP study
The support documents for follow-up HAZOP review should be:
- Engineering Flow Schemes or PFDs
- Utility Flow Schemes or UFDs
- Lists of site modifications since the original HAZOP study
- Process Safeguarding memorandum
- Operating and control philosophy, Cause and effect diagram
- Other support documentation
2. Documentation Review:
The documentation review is to check the availability and status of operating manuals, start-up/shutdown and emergency procedures. Following documents should be checked for availability and status:
- Operating manuals/procedures
- Emergency procedures
- Instruction of handling of chemicals
- Operation checklists on safety equipment
- Safeguarding Memorandum
- As-built P&IDs/PFDs
- Area Classification drawings, Plot Plans
- Fire Protection drawings
3. Technical HSE Site Review: could be carried out when the construction is nearing mechanical completion (about 90-95 % completion) and the site is reasonably accessible. The site review will concentrate on such issues as:
- Equipment operability and maintainability
- Outstanding punch list items from mechanical completion associated with PSSR
- Access and exit routes for operators and maintenance personnel
- Small-bore connections
- Location of emergency and safety equipment, warning signs
- Safe location of vent lines
- Locking systems
The PSSR checklists shall be completed by each discipline. A sample of operation checklist is given in following table:
Table 1 - Sample Operation Checklist