PRE-STRATUP SAFETY REVIEWS
(PSSR) MANAGEMENT
Document NO. HSE/PSM/SP/19
Philosophy
Pre-Startup 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.
Purpose
Pre-Startup 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.
General Requirements
A Pre-startup 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. Startup of new facility
7. Process or mechanical equipment that is temporary reactivated, borrowed or
leased.
8. Addition or modification of control logics, interlocks, instrument or electrical
devices.
PSSR PROCEDURE
PSSR shall include both a PSM ( PROCESS SAFETY MANAGEMENT )
element assessment and a physical inspection of the facility / equipment in the
field.
Responsibilities
The Area Owner (Operations Unit Managers or Other Area Incharges) is
responsible for initiating and coordinating the PSSR by pulling together
and assigning an appropriate review team and documenting the results. Area
owner 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 until:
a) Pre-Startup Safety Review (PSSR) is held per this procedure
b) The recommendations listed as required before startup have been
completed
c) The equipment is accepted for operation.
PSSR Steps
1. PSSR Request and Planning 3.Safety Critical List Updated for
Area owner or relevant Project New / Modified Equipment.
/ I&E section head or designate are 4.Startup, Shutdown,
eligible to initiate the PSSR Changeovers etc. Procedures in
request. Before launching such a place
request, the initiator must review the 5.Fire Protection Equipment /
PSSR checklists Pre-Startup Safety Sprinklers Extinguishers,
Review Form. If some of the critical Procedures Updated.
items are pending or incomplete, 6.Isolation valves handles OK.
then there view shall be postponed. Orientation is User Friendly.
Some of the critical items which are 7.Pressure Gauges Provided as
to be looked into before calling up a per Design.
PSSR are:
1. P&IDs Updated
2. Instruments / Interlocks
Diagrams Updated.
9. Fail Safe Valve Position Verified following groups, as appropriate:
by Operations, Process and 1. Safety interface, usually lead
Instrument. the PSSR.
10. Joint Loop Check Completed by 2. Production
Operations, Process and One or more first line supervisors
Instrument. and/or boardman and operators.
11. Conformance to Hazard 3. Technical
Classification. – Process Engineer
12. Grounding, Bonding/Lighting – Project Engineer
(Surge) Protection. – Machinery Engineer (if required)
– Inspection Engineer / technicians
2. Team Formulation 4.Maintenance Engineer /
The Owner with the help of project / Supervisor and/or technician
I&E engineer and Safety Section, shall 5. I&E Engineer / Supervisor and/or
select a multi disciplined team for technicians.
PSSR ensuring that all experienced 6. Other Personnel (outside expert if
resources are included and schedule required).
the PSSR.
A team may have members from the
Even for the smallest PSSR, such as
starting-up a single piece of equipment 4. PSM ( PROCESS SAFETY
(e.g., a pump, heat exchanger, or vessel), MANAGEMENT ) Elements
the team should have three or four Assessment
representatives from different backgrounds The team reviews the design, using the
(e.g., operations, maintenance, “Pre-Startup Safety Review Form /
design/technical and appropriate safety). Checklist” as a
This helps create a more searching and guide, to ensure that all elements of PSM
valuable review. (PROCESS SAFETY MANAGEMENT)
have been appropriately addressed. The
3. Team Meeting PSSR form is part of this procedure. It is
At the scheduled time and place, the PSSR intended to meet all the requirements of
team shall meet and shall: the PSM ( PROCESS SAFETY
MANAGEMENT ) Standard.
• Team leader shall confirm that all the
appropriate people are present as In this step fill Sections Process Safety
assigned by the owner. Information, Pre-start-up Safety Team
Members Names and. Brief Process
• Review the scope of the work that the
Information
PSSR will cover, using information such
as P&IDs, electrical diagrams, equipment
layouts, etc.
5. Field Inspection The team can challenge the
The PSSR team will then conduct a design basis if it has a direct
field inspection of the equipment, impact on personnel or process
using the Pre- Startup Safety safety but not to provide a
Review Form / Checklist. The solution.
purpose of this inspection is to 6. Deficiencies Communication
confirm that: Safety section shall provide one
• Construction and equipment is in copy of the PSSR form to the area
accordance with design owner and distribute copies to the
specifications. other interfaces mentioning all the
• Basic safety, health and deficiencies (both Before Startup
environmental items are checked, and After Startup) and any
one last time. suggestions. The distribution
• The facility is safe to startup. This could be on paper copy or
may be conditional depending through electronic media e.g.,
upon the completion of certain Safety Management
recommendations (exceptions or Information System (Safety
deficiencies). MIS).
7. Recommendations Tracking, Extension may be granted under
Follow-up and Closure following protocol
• The owner shall track all the • One time extension (1st time)
PSSR recommendations till their shall be approved by
completion. Department Manager with
• The stewardship of justification for extension
recommendations (in progress, • 2nd time / subsequent
pending / overdue or requiring extension shall be approved
approval) shall be stewarded by Manufacturing HSE
centrally by Safety Section. chairman / designated with
justification of extension.
8. Extension in Recommendations
Target Date
Extension in target date of a PSSR
recommendation may be required
under certain conditions (e.g. due to
non-availability of material, waiting
for vendor response etc).
PRE-STARTUP SAFETY REVIEW FORM /
CHECKLIST
Facility
Date
Project
Area/
No. building
Process Safety Information
Item Yes/No/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 & Measures taken
7. Operating procedures, safe practices, safety procedures and emergency
procedures are adequate
8. Training programs are in place for operators and mechanics
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)
