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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's a systematic review that's conducted before the startup of equipment, systems, or processes that have undergone maintenance (opens in new tab) or significant changes. This includes newly installed changes or inactivity for an extended period of time.
PSSR is particularly important in industries like oil and gas, chemical manufacturing, energy production, and pharmaceuticals, where the consequences of a failure could be severe. It is also mandated by regulatory bodies such as the Occupational Safety and Health Administration (OSHA) under OSHA 29 CFR 1910.199(I). 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.
Yes, PSSR is mandatory. Its purpose is to ensure that all safety measures are in place before starting a new process or restarting after significant changes. For example, it is a crucial step in hazardous industries for preventing accidents, protecting employees, and avoiding environmental damage.
Regulatory requirements include:
The primary objective of PSSR is to confirm that the installation of new or modified equipment complies with safety standards and operational protocols before it is activated. This includes validating that:
In relation to the third objective above, there are essential steps and procedures for teams involved in the PSSR process to be trained on. This includes:
A PSSR 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.
Health, safety, and environmental (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.
The PSSR execution process is a structured systematic approach to ensure that all safety measures, equipment, and procedures are in place and functional before starting or restarting industrial processes. The process is outlined with actions to take for each step in the table below:
Below is the PSSR workflow diagram stemming from a trigger event. This workflow diagram helps teams understand whether they need to conduct PSSR. You will note that if PSSR is a requirement, the personnel must perform a series of surveys (also known as questionnaires). These questionnaires typically cover various topics to ensure comprehensive safety checks.
Additionally, PSSR short form (seen as SF in the workflow below) refers to smaller changes and modifications to critical safety elements. In contrast, PSSR medium form (MF in the workflow) refers to a more comprehensive change on medium-scale projects. Generally, MF involves more work and a larger team.
PSSR is a fundamental practice that underscores a commitment to safety and operational excellence. It's not just nice to have; it's a regulatory requirement for industrial safety and operational integrity. By following regulations and a structured PSSR process, industries can mitigate risks and ensure a safe working environment.
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