Pre Startup Safety Review (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.

The purpose of the Pre Startup Safety Review is:

 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 should be 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.