The Importance of Pre-Startup Safety Review (PSSR):
Ensuring Safety Before Startup
The Pre-Startup Safety Review (PSSR) is an important step in the safety process for new and modified facilities. Before introducing hazardous chemicals or initiating complex industrial processes, it’s vital to ensure that all systems are set up for safe operation. A comprehensive PSSR helps identify potential hazards and guarantees compliance with operational standards. In this blog post, we’ll discuss PSSR, why it’s important, and how it contributes to a smooth and safe startup.
For a more detailed breakdown of the PSSR process, check out our second blog post Pre-Startup Safety Review (PSSR): A Step-by-Step Guide.
Here’s what you’ll find in this article:
What is Pre-Startup Safety Review (PSSR)?
A Pre-Startup Safety Review (PSSR) is an evaluation before beginning operations in a new or modified facility. Its primary purpose is to verify that all construction, equipment, and safety procedures are correctly implemented and meet the required standards for safe operation. As part of the Process Safety Management (PSM) system, PSSR is essential in identifying and managing potential risks before hazardous materials are introduced into the process.
Why is Pre-Startup Safety Review (PSSR) Important?
The primary aim of a PSSR is to confirm that all aspects of the operation are ready for a safe startup. Without this thorough review, unforeseen hazards or operational issues could arise. Here’s why PSSR is important:
- Safety Assurance: The PSSR checks that all safety measures are in place before startup, including safety equipment, emergency procedures, and employee training.
- Regulatory Compliance: OSHA’s 1910.119(l) requires a PSSR to establish that all necessary construction, safety procedures, hazard analyses, and employee training have been completed before starting operations with hazardous chemicals.
- Risk Reduction: The PSSR helps identify potential issues before they become significant problems during operation.
Key Components of a Pre-Startup Safety Review (PSSR)
To be effective, a PSSR must address several key areas:
- Construction and Equipment: Check that all equipment is installed according to design specifications and safety standards.
- Safety and Operating Procedures: Verify that safety, operating, maintenance, and emergency procedures are in place.
- Process Hazard Analysis (PHA): For new facilities, confirm a PHA has been completed and that any necessary actions have been implemented.
- Employee Training: Ensure that all employees involved in the process have received the required training.
- Hazard Identification and Evaluation: Be sure all hazards are identified, assessed, and addressed, particularly in modified facilities where process safety information may have changed.
Common Problems During Start-Up or Re-Start
Starting up a new or modified facility can be challenging, especially as issues often emerge during the transition from construction to operation. Some common problems include:
- Equipment Failures: New equipment may face issues as it begins operation.
- Hidden Hazards: Problems such as improper installation or design flaws may not be noticeable until the system is in use.
- Increased Personnel Exposure: The startup phase often involves more workers, raising the risk of accidents.
- Human Error: Inexperience with new systems or processes can lead to mistakes, especially under time pressure.
- New Hazardous Materials: Introducing new chemicals or processes may introduce unfamiliar risks.
- Limited Spare Parts: New equipment may require parts that are not readily available.
When is PSSR Conducted?
The PSSR should take place toward the end of the installation phase before commissioning begins and before the facility starts operations. It is a preparatory step to verify that everything is ready for safe operation.
Key points about the timing of PSSR include:
- Near Installation Completion: Conduct the review as the project nears completion to ensure all systems are in place.
- Before Commissioning: The PSSR should be completed before the commissioning phase, which involves testing systems and equipment.
- Pre-Operation: This review should be conducted prior to the actual startup of operations to confirm that safety and operational requirements are fully met.
How is Pre-Startup Safety Review (PSSR) Conducted?
The PSSR process is carried out in a systematic and organized manner, ensuring every aspect of the facility is ready for safe operations. Here’s an overview of how the process unfolds:
Preparation Stage:
- Assemble the Review Team: A cross-functional team is put together, drawing on expertise from key departments such as production, maintenance, safety, environmental, and engineering. Each member brings valuable insights to assess the various components of the operation.
- Gather Relevant Information: Prior to the review, all necessary documentation is collected, including process flow charts, chemical safety details, risk assessments, and design specifications. This ensures the team has a full understanding of the operation.
- Schedule the Review: The review is scheduled with sufficient time to conduct an in-depth inspection and a thorough field verification of the installation.
Review Stage:
- Project Overview Presentation: The project manager leads a detailed presentation to the review team, covering everything from design and construction standards to the materials used and any potential hazards identified during the planning stages.
- Document Evaluation: The team evaluates all essential documents, including operating procedures, emergency response plans, and maintenance protocols, to ensure they meet operational and safety requirements.
- On-Site Inspection: A physical walk-through of the facility takes place to verify that the actual installation aligns with the design specifications. This helps identify any differences between the planned and actual setup.
- Categorize Findings: The team organizes the findings based on their urgency and the potential impact they may have on safety, operations, and compliance. This helps prioritize issues that need immediate attention.
Post-Review Phase:
- Debrief and Action Plan: The PSSR team meets with the project management and operations teams to discuss the findings and agree on the necessary steps to address any issues. This establishes alignment on corrective actions.
- Final Report Creation: A comprehensive report is prepared, documenting all the findings, recommended actions, and a timeline for completion. This report serves as a reference for tracking progress and ensuring all safety and operational measures are implemented before startup.
The Pre-Startup Safety Review (PSSR) is essential to confirm that all safety measures, equipment, and procedures are in place before starting any new or modified industrial operation. This thorough review helps identify and address potential issues, ensuring the operation runs smoothly and safely.
For a deeper dive into the PSSR process, be sure to check out our second blog post Pre-Startup Safety Review (PSSR): A Step-by-Step Guide.
