What is Pre-Startup Safety Review (PSSR)?
- Pre-startup safety review (PSSR) is a process used in industries that handle hazardous chemicals or complex equipment to ensure that everything is safe and ready for operation before starting a new or modified process.
- It is a systematic review that is conducted before the startup of equipment, systems, or processes that have undergone maintenance or significant changes and emergency shutdown. This includes newly installed changes or inactivity for an extended period of time.
- It plays a role in managing risks associated with Management of Change (MOC) processes, and hazard identification techniques like Hazard and Operability Study (HAZOP), and overall compliance with health, safety, and environmental (HSE) standards.
Purpose of Pre-Startup Safety Review (PSSR)
- All systems are designed, installed, and functioning correctly.
- Hazards associated with the new or modified process are identified and mitigated.
- Workers are trained and capable of operating or maintaining the equipment safely.
- To ensure safety, operating, maintenance and emergency procedures are in place and adequate.
- To conduct technical and HSE reviews of documentation and on site.
PSSR team composition and their roles
A Pre-Startup Safety Review requires a cross-functional team of experts who bring knowledge and insights to the process. This team typically includes:
Process engineers: Evaluate whether the systems are functioning as per design specifications.
Maintenance personnel: Ensure the equipment is installed and maintained correctly.
HSE professionals: They identify potential safety and environmental risks and ensure that health and environmental standards are met.
Operations personnel: Provide operational insights, ensuring that systems are safe for day-to-day activities.
Management of change (MOC) coordinator: Ensures that any changes to the system or process have been properly documented, reviewed, and approved.
Pre-Startup Safety Review (PSSR) Execution Process
Step 1: Pre-planning and team formation
Assemble a multidisciplinary team: The PSSR team should include process engineers, maintenance personnel, health, safety, and environmental (HSE) professionals, operators’ staff, and a management of change (MOC) coordinator.
Define the scope: Determine what equipment, systems, or processes will be reviewed. This typically includes new installations, significant modifications, or restarts after prolonged shutdown.
Step 2: Review the pre-startup safety review checklist
Create or review a detailed PSSR checklist: The checklist will guide the team through all of the safety and operation aspects that need verification, including:
- Design and engineering specifications
- Equipment installation and integrity
- Safety systems and controls
- Hazard identification
- Training requirements
Step 3: Site inspection
Physically inspect the facility: The team conducts an on-site inspection of the equipment, machinery, and process areas.
Verify equipment installation: Ensure all installations are according to design specifications, and the equipment is safely integrated into the system.
Check safety systems: Inspect safety interlocks, alarms, shutdown systems, and other controls to ensure they are functional.
Step 4: Documentation and procedure review
Verify operating procedures: Ensure that procedures for the operations, maintenance, and emergency shutdown of equipment are accurate and up to date.
Management of change (MOC) review: Confirm that any changes to the process or equipment have been documented, reviewed, and approved according to the MOC process.
Regulatory documentation: Check if all permits, licenses, and regulatory approvals are in place.
Step 5: Operational tests
Conduct functional tests: Test the equipment and control systems to verify they perform as designed under different conditions. Standard practice is testing under normal conditions and emergency situations.
Simulate safety interlocks: Check that safety mechanisms, like emergency shutdown systems, are functioning correctly.
Step 6: Identification and resolution of action items
Identify any deficiencies or non-compliance: During the inspection, any deviations from design, incomplete installation, or other hazards are noted.
Address deficiencies: Action items are created for each identified issue. These may involve physical repairs, procedural changes, or further training.
Follow-up on open items: Ensure that all action items are resolved before moving on to the next step. The PSSR team must confirm that all safety gaps have been closed.
Step 7: Team sign-off and close out process
Final review and sign-off: Once all issues are addressed, and the team confirms that the system is safe, team members provide their sign-off.
Document completion of action items: Ensure that all identified hazards, issues, and action items are formally documented and resolved.
Final verification: The team should confirm that all safety systems, controls, and procedures are in place and operational before authorizing startup.
Step 8: Documentation and record keeping
Store completed PSSR documentation: All checklists, reports, hazard analyses, MOC documents, and action item resolution should be documented and stored for future reference and regulatory audits. Ensure records are kept in accordance with OSHA 29 CFR 1901.119(I).
Conclusion
By following this structured approach, a safe and compliant pre-start up can be ensured thereby minimizing the risks of accidents or operational failures.
For more information, contact us for our process safety management training.
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