Procedures Manual Volume Eight

PROCEDURES MANUAL Ref.
: HPSL/HUB/SAF/O/017 Page 1
VOLUME EIGHT Issue: A Level: 3 of 9
Subject: Approved Date
Pre-Start up Safety Reviews
(PSSR) 07/05/2018
Revalidation:
1.0 PURPOSE
Pre-Start up Safety Review (PSSR) provides a final checkpoint for new and modified equipment and
facilities to confirm that all appropriate elements of Process Safety and Risk Management have been
addressed satisfactorily and the equipment / facility is safe to start-up.
Pre-Start up Safety Reviews (PSSR) is mainly intended to make sure that alterations / additions to the
process or system do not create hazards to personnel at the site, surrounding facilities, community and
environment by inadequate, incomplete, or unauthorized design or installation. It is a final safety check
before close out of project e.g., a new process, modified equipment, new control system, material
change etc.
2.0 SCOPE
This document describes the requirement for complying with the Process Safety and Risk Management
element on Pre-Start up Safety Reviews for Hub Power Station.
The procedure explains guidelines to conduct effective Pre-Start up Safety Reviews (PSSR) by
formulating a team of multi-disciplined members. The process involves gathering of required team
members, asking questions by following PSSR checklist and then compiling the recommendations for
safe start-up of the facility. Procedure also includes requirement of tracking system for
recommendations.
This procedure is intended to confirm, prior to the start-up of a new or modified equipment / facility,
that:
1)
1) Construction is in accordance with design specifications.
2) The facility is safe to start-up, operate and maintain.
3) Process Hazards Analysis (PHA) recommendations addressed.
4) Elements of Process Safety Management (PSM) have been appropriately addressed, including the
following:
2)
a) Process Safety Information is available
b) Training, procedures and communications
c) Incorporating the new or revised equipment into area PSM systems
d) Operating and Maintenance Procedures have been adequately updated at final
commissioning
e) Quality Assurance requirements have been met
f) Mechanical Integrity plans have been established
g) Area Assessments completed
h) Emergency Planning and Response requirements have been addressed.
Written By: Saleem Qureshi Reviewed By: M. Islahuddin

HUB POWER SERVICES LTD. Ref.: HPSL/HUB/SAF/O/017 Page 2
PROCEDURES MANUAL Issue: A Level: 3 of 9
3.0 REFERENCES/DEFINITIONS
3.1 References
1) Hubco level-I procedure PSM 18-Pre Start-up Safety Review

2) HPSL/HUB/SAF/G/006 Accident, Incident, Near- Misses and Ill Health Reporting &
Investigation
3) HPSL/HUB/ENG/005 Plant Modification
3.2 Definitions
1) Approve
A formal decision to proceed with implementation of a change after all criteria of the review
procedure is found to be acceptable.
2) Change
Any addition or deletion to the equipment / facilities, or a modification involving substitute
materials, other than "repair or replacement in kind"; any change in materials used in the process
such as raw materials , or a shift in operations to conditions outside the established process,
mechanical or technical design envelope.
3) Commission
To put a change into service (start-up).
4) Decommission
To shut down, drain and clean if necessary, and dismantle, or to otherwise return a change to the
original configuration.
5) Evaluate
To make an assessment of an implemented change to determine the need, alternatives, and effects
of the potential change on such things as design, operations, maintenance, safety, health, and
environment.
6) Evergreen
Maintaining Controlled Documentation up to date, accurate, and reflecting all changes in a timely
manner.
7) Implement
The coordination and execution of the activities associated with the achievement or construction
of a change.
8) Owner
The nominated Operation Coordinator (Senior Engineer Ops/Shift Manager) or other Area owner.
9) Permanent Change
A change which is considered long term and durable.
10) Repair or Replacement In-Kind

A replacement or repair of a part, or maintenance on the facility which does not modify or alter
the facility in any way. The replacement in-kind brings the facility back to its original condition.
11) Review
An examination of a change by a formal review team with regards to approved engineering design
(mechanical, instrument or electrical), operating, safety, health, legal and environmental
requirements and practices.
3.3 Abbreviations
API American Petroleum Institute PM Preventive Maintenance

PLC Programmable Logic Controllers PPE Personal Protective Equipment
EPA Environmental Protection Agency PSI Process Safety Information
HSE Health, Safety and Environment PSM Process Safety Management
MOC Management of Change PSSR Pre-Start up Safety Review
OSHA Occupational Safety and Health SOE Senior Operation Engineer,
Administration
P&IDs Process and Instrumentation Diagrams SOC Safe Operations Committee
PFDs Process Flow Diagrams SOP Standard Operating Procedure
PHA Process Hazards Analysis Sub Sub SOC
SOC
PHR Periodic Hazard Review E&IH Environmental and Industrial Hygiene
4.0 PROCEDURE
PSSR shall include both a PSM element assessment and a physical inspection of the facility / equipment
in the field
4.1 Responsibilities
1) Production Manager
The Production Manager is responsible for coordinating the PSSR by pulling together and
assigning an appropriate review team and documenting the results. Area owner (operator) can
take help from respective project / maintenance engineer to conduct the audit. While assigning a
team for PSSR, the owner shall also nominate a leader for the PSSR.
The area owner shall not allow operation of new or modified equipment (as listed above) until:
a) Pre-Start-up Safety Review (PSSR) is held as per this procedure

b) The recommendations listed as required before start-up have been completed
c) The equipment is accepted for operation.
2) Maintenance Manager
The Maintenance Manager is responsible for the overall management of the PSSR process and
ensure required trained maintenance team members are available to complete the PSSR process.
The Maintenance Manager shall ensure that all Maintenance sections comply with the
requirements of this procedure.
3) HSE Section
HSE Section shall:
a) Document the Post PSSR findings

b) Compile the deficiencies and recommendations or suggestions of the PSSR
c) Circulate deficiencies and recommendations through electronic mail or hard copies to
relevant interfaces.
4) Performance and Planning Coordinator
Performance and Planning Coordinator is responsible for ensuring that planning section along
with project engineering, Instrument and Electrical Maintenance and safety shall develop a
detailed PSSR plan for planned Outages mentioning project description, date and time of PSSR
and resource allocation.
4.2 General Requirements
A Pre-start up Safety Review (PSSR) is required for:
1) All new / modified facilities for which the modification necessitates a change in the Process Safety
Information (PSI) package. This would include new facilities installed as a major project or
modification, requiring usage of Management of Change protocol.
2) Replacement of process or mechanical equipment with non-identical equipment – change in
metallurgy, shape, internals, dimensions, speeds etc.
3) Introduction of new process or chemicals.
4) New installation of a piping system or extensive modifications to an existing piping system.
5) New installation of process equipment.
6) Start-up of new facility.
7) Process or mechanical equipment that is temporary reactivated, borrowed or leased.
8) Equipment judged to have the potential for impacting process safety, for example:
 Any temporary equipment attached to the system.
9) Addition or modification of control logics, interlocks, instrument or electrical devices.
10) New or leased large power or shop tools, electrical generators that affect process safety.
Note: Major safety, environmental, ergonomic or regulatory issues envisaged from the facility when
put in service.
4.3 Additional Guidelines Depending on Project / Change Scope
1) Significant Capital Expenditures or Complex Operations
Where the change involves significant capital expenditures and one or more complex unit
operations with hazardous materials and activities, then it is recommended that the PSM element
assessment be conducted by either a site resource (first party) or Off-site head office (second
party) resources. It may be helpful to carry out a two-part review.
a) The first part review should take place when design is complete and construction is at an
early stage or has not yet begun. This allows operating procedures, emergency planning and
training to be upgraded well in advance of start-up.
b) The second part of the review can then take place just prior to introduction of hazardous
substances and focus on checking that construction and equipment are in accordance with
design.
2) Larger Capital Projects
The PSM element assessment can be done using either the PSM audit checklist (by first- or
second-party audit) and by using a PSSR checklist given in Pre-Start up Safety Review
Form/Checklist (attachment #1).
3) Smaller Projects / Modifications
For smaller projects / modifications, the PSM element assessment can be conducted using a PSSR
checklist. The PSSR team should select relevant parts of a PSSR checklist given in Pre-Start up
Safety Review Form / Checklist (Attachment #1) to review, as appropriate, for the project /
modification.
4.4 PSSR Steps
1) PSSR Request and Planning
Responsible Engineer is eligible to initiate the PSSR request. Before launching such a request, the
Responsible Engineer must review the PSSR checklists given in Pre-Start up Safety Review Form
/ Checklist (Attachment #1) to assess the completion of the work. If some of the critical items are
pending or incomplete, then the review shall be postponed. Some of the critical items which are to
be looked into before calling up a PSSR are:
a) P&IDs Updated.
b) Instruments / Interlocks Diagrams Updated.
c) Safety Critical List Updated for New / Modified Equipment.
d) Startup, Shutdown, Changeovers Operation Instructions in place
e) Fire Protection Equipment / Sprinklers Extinguishers, Procedures Updated.
f) Final list prepared by operations reviewed and point removed.
g) Isolating Valves locking mechanism is acceptable. Orientation is User Friendly.
h) Electrical Isolation mechanism is acceptable. Orientation is User Friendly
i) Pressure Gauges Provided as per Design.
j) Temperature Gauges Provided as per Design.
k) Fail Safe Valve Position Verified by Operations, Process and Instrument.
l) Joint Loop Check Completed by Operations, Process and Instrument.
m) Conformance to Hazard Classification.
n) Grounding, Bonding/Lighting (Surge) Protection.
i)
2) Outage PSSR Planning
Planning section along with Responsible Engineer shall develop a detailed PSSR plan for planned
outages mentioning project description, date and time of PSSR and resource allocation.
While developing the plan, one must consider following:
a) The clash of PSSR with other activities in that particular area

b) Enough time shall be planned to rectify the deficiencies highlighted in the overall activity
bar chart.
c) Facility completion / readiness vs. resource availability.
3) PSM Elements Assessment
The team reviews the design, using the Pre-Start up Safety Review Form / Checklist Pre-Start up
Safety Review Form / Checklist (attachment # 1) as a guide, to ensure that all elements of PSM
have been appropriately addressed. The PSSR form is part of this procedure. It is intended to meet
all the requirements of the PSM Standard.
In this step fill Process Safety Information, Pre-start-up Safety Team Members Names and Brief
Process Information.
a) PSI is documented, communicated, and readily available to facility owner

b) Basic safety, health and environment considerations are proper.

c) Construction and equipment are in accordance with design specifications
d)
e) Spot check the quality of operating and maintenance procedure (including safety and
emergency response procedures) to ensure that they are consistent with PSI and
requirements defined in the PSM on Operating and Maintenance Procedures and Emergency
Planning and Response.
f) Training of each operating and maintenance employee has been completed.
g) PHR recommendations have been addressed and actions necessary for start-up have been
completed.
h) Spot check that:
i) Quality Assurance steps or hold points have been ensured during construction phase
and are consistent with the criteria defined in the PSM on Quality Assurance.
ii) Mechanical integrity systems have been established and equipment test and inspection
schedules are complete and in place. Such items can be included “after
commissioning” deficiencies and recorded in the PSSR findings.
4) Team Formulation
The Area Owner with Responsible Engineer shall select a multi-disciplined team for PSSR
ensuring that all appropriate resources are included and schedule the PSSR (to coincide with the
expected completion and availability of the equipment / facility). A team may have members from
the following groups, as appropriate:
a) Safety interface
b) Production
c) One or more first line supervisors and/or operators.
d) Technical
e) Project Engineer
f) Maintenance Engineer / Supervisor and/or technician
g) Instrument and Electrical Maintenance Engineer / Supervisor and/or technicians.
h) Other Personnel (outside expert if required).
j)
While selecting the members for review team, the Owner shall consider pulling up of the key
personnel by considering:
 Experience of the individual vs. criticality and complexity of the project being reviewed.
 The key individuals are not directly involved in the project itself to make sure facility has
a final review from fresh eye.
Even for the smallest PSSR, such as starting-up a single piece of equipment (e.g., a pump, heat
exchanger, or vessel), the team should have three or four representatives from different
backgrounds (e.g., operations, maintenance, and appropriate safety). This helps create a more
searching and valuable review. People who operate or maintain the facility (e.g., an operator and
a technician) should be included.
5) Team Meeting
The leader of the PSSR team should foster an open atmosphere where the project team members
take the review as an opportunity to upgrade the process safety of the facility and do not become
defensive of the design or preparations for start-up.
At the scheduled time and place, the PSSR team shall meet and
a) Team leader shall confirm that all the appropriate people are present as assigned by the
owner.
b) Shall Review the scope of the work that the PSSR will cover, using information such as
P&IDs, electrical diagrams, equipment layouts, etc.
6) Field Inspection
The PSSR team will then conduct a field inspection of the equipment, using the Pre-Start up Safety
Review Form / Checklist (attachment # 1).
The purpose of this inspection is to confirm that:
a) Construction and equipment is in accordance with design specifications.

b) Basic safety, health and environmental items are checked, one last time.
c) The facility is safe to start-up. This may be conditional depending upon the completion of
certain recommendations (exceptions or deficiencies).
During the inspection, every team member will contact the PSSR leader or designated scribe for
documenting the identified deficiencies on PSSR form. The field inspection should be an
interactive, questioning activity whose purpose is to identify any problems with the physical
installation and to ensure that no potential safety problems exist at the human / equipment
interfaces.
The team can challenge the design basis if it has a direct impact on personnel or process safety but
not to provide a solution.
7) PSSR Completion
After completing the field inspection the team will re-assemble. PSSR team leader will ensure
following:
a) The inspection has been properly completed.

b) All deficiencies posing safety concerns have been recorded in checklist.
c) Develop a plan to deal with any deficiencies or to re-inspect the equipment (if the team
considers this necessary).
d) Complete the PSSR checklist, listing any deficiencies that must be corrected before Startup
of the equipment, as well as deficiencies that can and will be corrected after Startup.
e) All members of the PSSR team as well as the leader shall sign the PSSR form to confirm
that they participated in PSSR and are in agreement with the outcome of the PSSR
inspection.
8) Communication
Responsible Engineer shall provide one copy of the PSSR form to the area owner and distribute
copies to the other interfaces mentioning all the deficiencies (both Before Start up and After Start
up) and any suggestions. The distribution could be on paper copy or through computerised
management system.
9) Facility Commissioning Authorization
a) Upon resolution of any deficiencies that were to be completed Before Start-up, the area
owner shall sign the PSSR checklist to authorize the start-up of the equipment or facility.
An electronic record having authorization from the owner of the facility may be acceptable.
b) The area owner will ensure that a copy of the PSSR form is maintained until all the PSSR
recommendations have been closed. Centralized electronic records can be considered as
records.
c) Once all deficiencies found in the PSSR have been addressed / corrected, the area owner
shall close out the PSSR by signing the form as “complete” and file the completed PSSR
form. Completed PSSR forms will be filed in the appropriate area files. Electronic copies
saved in the centralized electronic system.
10) Recommendations Tracking, Follow-up and Closure
a) The Responsible engineer shall track all the PSSR recommendations till their completion.
b) The stewardship of recommendations (in progress, pending / overdue or requiring approval)
shall be done centrally by HSE Section.
c) The status of all the PSSR recommendations shall be stewarded on monthly basis.
11) Recommendations Cancellation
At times some of the PSSR recommendations might not prove to be aligned with the standards or
codes, such recommendations or highlighted deficiencies shall be dropped by documenting the
justification and getting approval from the SOC chairman.
3)
4.5 PSSR Documentation
All the PSSR deficiencies shall be listed and justification of their completion status shall be filed in the
project close out report. This is the responsibility of concerned responsible engineer.
4.6 PSSR Form and Checklists
The attached PSSR Form / Checklist includes items pertinent to common jobs. The checklist is not
intended to be all inclusive. Other items may require review, depending on the equipment being
inspected.
Additional checklist items considered by the PSSR team should be listed.
For Instrument and Electrical Projects, Instrument Project Audit Checklist (Attachment # 2) and
Electrical Project Audit Checklist (Attachment # 3) shall also be used in addition to PSSR Form /
Checklist.
4.7 PSSR Element Audit
SOC shall ensure that audit of PSSR is being carried out via Auditing element of PSM. Following are
some guidelines:
a) PSSRs are being done when needed

b) Before Start-up, recommendations are completed.
c) A file of PSSR should be compiled for comparison with changes and for PSM documentation.
4.8 Exceptions
1) Identical Repeated Component Installation
In case of facilities change that include a large number of virtually identical small changes that
are made over a long period of time carrying out individual PSSRs on every change may be
inappropriate and time consuming.
In such cases, with the approval of the SOC, a customized inspection form may be developed and
used to document inspection of each installation by the responsible engineer carrying out the job
and audited by another employee on the customized inspection form. Once the entire facility or
modification is installed or completed, the PSSR process shall be completed as appropriate, and
the individual inspection forms attached to it. The complete PSSR form should then be approved,
closed, and filed as per this procedure.
2) Exemptions
Following items do not fall under the scope of this procedure provided they do not contain
hazardous material or are not attached to process. However, special teams may be assigned to
inspect or review before putting them in service:
a) Small hand type power tools (e.g., impact wrenches, drill motors, test meters) need only be
inspected by the equipment owner (shops, Instrument and Electrical Maintenance,
inspection) and maintenance groups and are not covered by this procedure e.g., Cranes,
Welding Machines, High Pressure Water Jetting Machine for cleaning purpose etc.
b) Standalone modifications or updates to procedures, checklists or log-sheets
c) Box-ups
d) Test runs which do not involve equipment modifications or changes
e) Equipment repairs – shall be covered through box-up certificates signed by relevant
interfaces.
f) Facilities / plant start-up after Outage.
k)
5.0 ATTACHMENT
1) Pre-Start up Safety Review Form / Checklist

2) Instrument Project Audit Checklist
3) Electrical Project Audit Checklist
Hub Power Station
Pre-Start up Safety Review Form / Checklist

Plant Area Date
Mod/Project No. KKS
Mod/Project Description
Mod/Project Engineer
1. Process Safety Information

Item Yes/No/ Remarks
NA
1. Physical and hazardous properties of all materials documented
2. Process design basis documented
3. Design basis for equipment and safety devices documented (above
communicated to proprietor and filed to be readily available to
operating personnel)
4. Equipment fabricated and installed according to specification
5. Maintenance procedures and preventive maintenance program are
adequate to ensure mechanical integrity throughout life of the process
including the spares
6. Quality Assurance Steps and Measures taken
7. Operating Instructions, Safety Procedures and Emergency Procedures
are adequate
8. Training programs are in place for Operators and Maintenance
9. Management of Change procedures to be used for all changes
10. Process hazards analysis/process hazards review completed and
recommended actions completed
11. Emergency plan based on consequence analysis (people trained)
2. Pre-start-up Safety Team Members Names

Interface Name Interface Name
Operations HSE
Mechanical Project
Electrical
Instrument
Team Leader
3. Brief Process Information

Design intent of facility
Process Materials Hazards
Operating Temperature Operating Pressure
Electrical Classification (if
applicable)
Note: PSI section has to be filled before the field audit.
Attachment # 1
HPSL/HUB/SAF/O/017-F1
Hub Power Station
4. Detailed Checklist
a. Guidelines
Yes The item is available or completed to its requirements.
NA The item is not applicable in this case.
No The item is required but not done, mention any deficiencies or recommendations in
remarks column.
Reqd. for Start-up (S/U) The item is required for start-up of the facility, that is, Before Start up.
b. Process Safety Information

Reqd
Category Yes NA No Remarks
for S/U
1. P&IDs Updated.
2. Isometrics Available Updated.
3. Instruments / Interlocks Diagrams Updated.
4. Updated Underground Piping / Electrical
Cables Drawing Available.
5. Design Documentation Complete.
6. Safety Critical Service Documentation
Complete.
7. Safety Critical List Updated for New /
Modified Equipment.
c. Process Hazard Analysis

Reqd
for S/U
8. Process Hazards Review Required and
Completed Prior to Start-up?
9. PHR / PHA Start-up Recommendations
Complete?
d. Operating and Maintenance Procedures – Provided / Updated

Reqd
for S/U
10. Equipment Description Added in
Procedures / Manuals.
11. Startup, Shutdown, Changeovers etc.
Procedures
12. Process Emergency Handling Procedures.
13. Process Control Guidelines Provided
14. Alarms & Instrument Listing.
15. Alarms & Instrument Checks.
16. Analyzer Maintenance/ Calibration.
17. Maintenance Procedures
18. Building Safety Instructions.
19. Fire Protection Equipment / Sprinklers
Extinguishers, Procedures Updated.
20. Safety Shower / Eye Washes Procedures
Updated.
21. Spill Containment Procedure Updated /
Provided.
Attachment # 1
Hub Power Station
e. Piping and Equipment

Reqd
for S/U
22. Piping and Flanges as per specification.
23. Correct Materials of Construction used.
24. Correct Gaskets / Bolting. No short / long
bolting.
25. Supports OK, No Vibrations foreseen.
26. Correct Insulation for Intended Service.
27. Tracing Completed, Tagged & Identified.
28. Isolation Valves / Handles OK. Orientation
is User Friendly.
29. Stored Energy Sources Identified.
30. Low Point Drains / Flushes provide. Purge
Connections Adequate for Maintenance.
31. Process / Service Connections Correct.
32. Pressure / Hydro Test Completed.
33. Relief Device Installed / Directed
Properly. Record Updated.
34. Shielding for Flanges, Valves etc.
provided.
35. 3-Way Valve Orientation.
36. Makeshift Devices Eliminated, (Extension
Cords, Ropes and Hoses etc.)
37. Hydrogen Piping Standards Followed.
38. Strainers Provided as per Design /
Temporary Strainer with Correct Material
f. Rotating Equipment
Reqd
for S/U
39. Necessary Guards Installed.
40. Lubrication and Alignment Complete.
41. Emergency Facilities/Shutdown
42. Correct Rotation Checked by Process,
Machinery, Projects.
43. PM Records in Place.
44. Spare Parts Available.
45. Hydraulic Systems Installed Per Design
and Checked Prior to Start-up.
46. Lifting and Rigging Provisions for
Maintenance.
g. Quality Assurance
Reqd
for S/U
47. Onsite Inspections at Equipment Vendors
Shops Done.
48. Installation per Vender’s Instructions.
49. Non-destructive Testing done.
50. Materials of Construction Verification
done.
51. Overpressure Protection & Vent Systems
Tested.
Attachment # 1
Hub Power Station
g. Quality Assurance
Reqd
for S/U
52. Pipe Codes Adherence Verified, Including
Gaskets, Bolts, Valves, Hoses, Expansion,
Pipe Schedule, etc.
h. Instrumentation
Reqd
for S/U
53. Pressure Gauges Provided as per Design.
54. Temperature Gauges Provided as per
Design.
55. Fail Safe Valve Position Verified by
Operations, Process and Instrument.
56. Joint Loop Check Completed by
Operations, Process and Instrument.
57. Analyzer Check Completed.
58. Spare Parts Available.
59. Equipment Meets the Process Material
Requirements.
i. Electrical Equipment
Reqd
for S/U
60. Conformance to Hazard Classification
(Area Classification)
61. Grounding, Bonding/Lighting (Surge)
Protection.
62. Safety or Process Interlocks / Alarms
Checked Jointly by Operations, and I&C
or Electrical.
63. Electrical Inspection Complete.
64. Emergency Switches Required? Conduits
and Boxes Sealed?
65. Electrical Breakers cannot be racked out in
Energized Position (for draw-out type)
j. Structures
Reqd
for S/U
66. Doors – Ramps – Fire Doors, Walls.
67. Exits (Traffic Flow, Door Swings, And
Emergency Escape).
68. Safety Chains, Handrails, Guard Rails
Installed where Required.
69. Walkways, Ladders, Stairs Provided.
70. Overhead Hazards Removed.
71. Fire Proofing. Done where Required
72. Platforms Provided Where Needed for
Operations / Maintenance.
Attachment # 1
Hub Power Station
k. Labelling
Reqd
for S/U
73. KKS Tags
74. Flow Direction Identified.
75. Instrument (Transmitters, Gauges, Panel
boards, DCS).
76. Electrical (Switches, MCCs Buttons, Local
Disconnects).
77. High Voltages Labeled?
78. Hot Surfaces Marked?
79. Equipment (Tanks, Pumps, Condensers,
Exchangers, Feeders, Monorails, Hoists,
etc.).
80. Other (Hydrogen, Air).
l. Emergency Planning and Response

Reqd
for S/U
81. Spill Containment Facilities Provided.
82. Fire Protection Equipment / Sprinklers
Extinguishers Provided Where Required.
83. Safety Shower / Eye Washes Procedures
Updated.
84. Emergency Response Procedures Updating
Required.
85. MSDS Available (submit to HSE to update
system)
86. Evacuation Alarms Available?
87. Floor Drainage, Curbs and Dikes in Good
Condition.
88. Fire Fighting Provisions & Access.
m. General Items
Reqd
for S/U
89. Accessibility for Maintenance/ Operations.
90. Lockout / Tag out Provisions in Place,
Training Complete.
91. Any Tripping Hazards or Pinch Points.
92. Painting / Safety Painting.
93. Safety Rules or Signs Installed.
94. Area and Spot Ventilation Adequate.
95. Noise Level Measured.
96. Acoustic, Thermal, Noise Insulation
Installed.
97. Lighting Adequate / Emergency Lights
Adequate.
98. Special Operating Tools Provided Where
Needed.
99. Hidden /Stored Energy Sources Identified?
100. Mechanical/Contractor Cleaned-up Area.
101. Training.
Attachment # 1
Hub Power Station
PSSR Completion Certification
Mod/Project Description
Mod/Project Engineer KKS
Before Start up Deficiencies / Points

Completed
Deficiencies to be corrected before Start up Responsibility
(Sign)
Before Start-up Recommendations have been completed

Operations
Representative Name
Signature Date
After Start up Deficiencies / Points

Completed
Deficiencies correction Not Required before Start up Responsibility
(Sign)
Inspected & Approved by Team Members and Leader

Clearance
Interface Signatures Interface Signatures
Operations HSE
Mechanical T&P
Electrical I&C
Team Leader
Project close out approved by Maintenance/T&P Manager Date
Attachment # 1
Hub Power Station
Instrument Project Audit Checklist
Description Yes No NA
Has IMD Sub-SOC been held for the project (if required )
JB’s Inspection
1 JB complies with area classification? (if required)
2 New JB has a number painted on it.
3 Sealing of the JB door/cover satisfactory for light rain.
4 Lugs properly pressed and terminated.
5 No loose connections. (Check a few wires).
6 Shield not connected at inst. end and is grounded at control system.
7 Proper tagging on all cables with core marker.
8 Cable’s entering JB properly glanded with no opening for dust.
9 On JBs, no top entry for cables.
10 Any spare cable entry points have blind plug.
11 Segregated AC and DC signals keeping in view voltage levels.
12 If any shared Instrument and Electrical signal, has checklist given in Instrument
and Electrical procedure been filled.
Control Valve Checks
1 Tag plate installed.
2 Tag name painted.
3 If valve safety critical, is it painted red.
4 Close IAS and check valve fail-safe.
5 Block and bleed available for isolation.
6 Hand jack auto to hand-jack and back to auto procedure displayed?
7 Convenient access exists to hand-jack for operator. If not, get stand constructed and
placed.
Solenoid operated valve Checks
1 Air bleed port faces down so dust cannot accumulate.
2 Bug-proof installed.
3 No mixed fitting e.g. brass to SS. (If found, rectify)
Cables
1 Cable trays are not overloaded.
2 Fire proofing of the cable trays in the required area done.
3 Cables are away from steam-lines or other heat sources.
4 Distance kept between instrument signal & electrical cables
5 OT’s on conduits have T facing downwards so water does not fill up.
General Field instrumentation
1 Instruments meet area maximum ambient temperature rating?
2 If ambient rating near borderline is equipment installed in shade.
3 Location allows easy access for maintenance.
4 Tag plates installed on instruments.
5 Isolation / depressurization arrangement provided (Block & Bleed)
6 Check IAS supports leading to device are firm and sturdy.
7 If any spare thermowells or tapings, plugged and blinded properly?
8 If sq. root required, configure only in DCS, not in transmitter.
Attachment #2
Hub Power Station
Special Instructions to Operator
1 Any special procedure to take equipment in service, has been put up? e.g. If new
control-valve with spring loaded glands, pressurize slowly.
Checklist for recording post - commissioning data (reference & initial observation) has been
developed?
Control System
1 In Control system (DCS, PLC) cabinet, check terminations
2 Have new points and schematics been configured and verified
3 Have you taken a fresh backup after the changes, irrespective of backup frequency?
Attachment #2
Hub Power Station
Electrical Project Audit Checklist

General
1. MV cable termination or jointing is on
2. In case, any instrument signal coming to Electrical circuit or vice versa, verification check
list as given in Electrical procedure is duly filled
3. In case any protection devices are employed, these are bench tested & circuit integrity
has been checked by a dummy test from the sensor to final trip element.
4. All isolating breakers have proper lock out and tag out arrangement
5. Checklist for recording post-commissioning data (Reference & initial) has been
developed.
6. Area illumination is sufficient.
7. Smoke detectors are installed where required.
8. Air-conditioning is sufficient where required.
JBs / DBs inspection:

1 JB / DB complies with area classification?
2 New JB / DB has been tagged properly.
3 JB / DB is properly grounded.
4 Sealing of the JB / DB carried out against water ingression.
5 Lugs properly pressed and terminated.(spot-check few)
6 No loose connections at terminals & joints. (Spot check a few wires).
7 Proper tagging on all cables with core marker is available.
8 JB TB's drawing placed in envelope in JB? (Optional but preferable)
9 Cable's entering JB properly glanded with no opening for dust.
10 Any spare cable entry points have blind plug.
11 No un-insulated bus-bars / joints.
12 No left over material & tools present inside.
13 Secondary winding of CTs, if used, is grounded at one end.
14 cables , entering or leaving metallic conduits are protected from sharp edges
15 Fire catching material like wood is not present inside.
Attachment #3
Hub Power Station
Yes No NA
Cables/Conduits/Fittings
1 Cable trays are not overloaded.
2 Fire proofing of the cable trays in the required area done.
3 Cables are away from steam-lines or other heat sources.
4 Distance kept between instrument signal & electrical cables
5 OT's on conduits have T facing downwards so water does not fill up.
6 Sealing of conduits done
7 Armor is grounded at one terminal point
8 Cable bending radius is as per manufacturer's recommendations.
9 Conduits for cables, if used, are chosen in a manner to ensure recommended free space
(40%) within the conduit.
10 Cable route markers are installed and protruded on surface.
11 Lugs are properly punched at core conductors.
Switch Gear/Starters/Circuit Breakers

1 Are they capable of being locked out only in de-energized position?
2 Multiple circuit breakers using different tool are distinguished for specific service e.g.,
color.
3 Labels are correct & verified thru testing.
Motors / Transformers
1 Motor is as per area classification
2 Motor name plate matches with actual requirement.
3 Motor / Transformer is grounded
4 Check free rotation of motor before switching it ON.
5 Coupling guard is installed at motor coupling
6 Dummy test of Motor control circuit carried out before switching it ON
7 All accessories of transformers are mounted and fitted on its body
8 Functionality of Bucholz relay is established through dummy test before switching
ON the transformer.
9 Silica jell is filled in breather and its color is OK.
Special Instructions to Operator

1 Any special procedure to take equipment in service, has been put up?
Attachment #3

Procedures Manual Volume Eight

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PROCEDURES MANUAL Ref.

2) The facility is safe to start-up, operate and maintain.

3) Process Hazards Analysis (PHA) recommendations addressed.

Written By: Saleem Qureshi Reviewed By: M. Islahuddin

PROCEDURES MANUAL Issue: A Level: 3 of 9

1) Hubco level-I procedure PSM 18-Pre Start-up Safety Review

10) Repair or Replacement In-Kind

PROCEDURES MANUAL Issue: A Level: 3 of 9

API American Petroleum Institute PM Preventive Maintenance

a) Pre-Start-up Safety Review (PSSR) is held as per this procedure

HSE Section shall:

a) Document the Post PSSR findings

PROCEDURES MANUAL Issue: A Level: 3 of 9

4) Performance and Planning Coordinator

4.2 General Requirements

A Pre-start up Safety Review (PSSR) is required for:

4.3 Additional Guidelines Depending on Project / Change Scope

1) Significant Capital Expenditures or Complex Operations

2) Larger Capital Projects

PROCEDURES MANUAL Issue: A Level: 3 of 9

3) Smaller Projects / Modifications

4.4 PSSR Steps

1) PSSR Request and Planning

While developing the plan, one must consider following:

a) The clash of PSSR with other activities in that particular area

3) PSM Elements Assessment

a) PSI is documented, communicated, and readily available to facility owner

PROCEDURES MANUAL Issue: A Level: 3 of 9

b) Basic safety, health and environment considerations are proper.

PROCEDURES MANUAL Issue: A Level: 3 of 9

The purpose of this inspection is to confirm that:

a) Construction and equipment is in accordance with design specifications.

a) The inspection has been properly completed.

9) Facility Commissioning Authorization

PROCEDURES MANUAL Issue: A Level: 3 of 9

10) Recommendations Tracking, Follow-up and Closure

11) Recommendations Cancellation

4.6 PSSR Form and Checklists

Additional checklist items considered by the PSSR team should be listed.

4.7 PSSR Element Audit

a) PSSRs are being done when needed

1) Identical Repeated Component Installation

PROCEDURES MANUAL Issue: A Level: 3 of 9

1) Pre-Start up Safety Review Form / Checklist

Pre-Start up Safety Review Form / Checklist

1. Process Safety Information

2. Pre-start-up Safety Team Members Names

3. Brief Process Information

Note: PSI section has to be filled before the field audit.

b. Process Safety Information

c. Process Hazard Analysis

d. Operating and Maintenance Procedures – Provided / Updated

e. Piping and Equipment

l. Emergency Planning and Response

PSSR Completion Certification

Before Start up Deficiencies / Points

Before Start-up Recommendations have been completed

After Start up Deficiencies / Points

Inspected & Approved by Team Members and Leader

Project close out approved by Maintenance/T&P Manager Date

Instrument Project Audit Checklist

Electrical Project Audit Checklist

JBs / DBs inspection: