Pre-Start-Up Safety Review english MAKE SURE EVERYONE UNDERSTAND THEIR PART IN THE RESCUE PROCEDURE AND EQUIPMENT IS READILY AVAILABLE

Pre-Start-Up Safety Review (PSSR)
HSSEBL_001_CO_010

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Agenda
1 PSSR Introduction
3 Types of PSSR Findings
2 PSSR Process
4 Checklist of PSSR
6 Questions/Quizzes
5 Team Exercise

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Objective
• To serves as the final check before energization.
• To ensure the risks during start-up have been identified and are mitigated to
an acceptable level, and that all design requirements have been
implemented and the facility can be safely operated.

Key Changes
Confidential Internal - )‫(داخلي‬ ‫مقيد‬

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What are Changes in PSSR
OLD System NEW System
1) No stand alone system available with R&R, touch
based with MOC
1) PSSR stand alone system is available, clear role &
responsibilities defined
2) No requirements for Post Outages or Shut Down
Activities
2) Covers all aspects as per Internationally
Recognized Practices
3) Very weak PSSR list available not covering
important HSE aspects
3) Various checklist and explicit requirements are
addressed
4) No effective Mechanism of monitoring the findings
and tracking actions
4) Covering KPIs with trackers
4) No process is defined 5) Standard covers

Introduction to PSSR
Confidential Internal - ) (
‫داخلي‬ ‫مقيد‬

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What’s New?
Covered in Details
When to
conduct
How to conduct
PSSR Team
Formation
PSSR Findings
and
Classification

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Situations requiring PSSR
1. After a capital expenditure project has been completed.
2. In case of technical modifications, as part of the Management of Change (MOC) process, see
Management of Change (MOC). For other changes, the need for PSSR is determined by the MOC
Committee.
3. In the event of major maintenance work or a turnaround.

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Situations not requiring PSSR
In the following situations the application of PSSR is not required:
• A startup after an unplanned / emergency shutdown. This shall be addressed in
the respective Safe Operating Procedure (SOP).
• Any changes that do not require MOC – activity to be evaluated, refer to CMS
(Management of Change)

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PSSR for capital expenditure project
Construction and equipment
installation is in accordance with
codes, standards, and design
specifications.
Hazard identification and risk
assessment have been
conducted in accordance with
(HSSE Risk Management) and
(HSSE in Projects),
Checks, testing and calibration of
electrical equipment and
instrumentation has been
completed.
Pre-operational activities that
could prevent energisation
Field inspection items have been
addressed.
Field safety inspection items
have been confirmed.
All valves are in the appropriate
position, locked where
necessary.
Initial, startup, normal and
emergency operating, and
maintenance procedures are in
place.
Training for operational staff has
been provided for all concerned
personnel.
Ensure emergency response
plan(s) have been developed and
emergency response resources
are trained.
Any additional required HSSE
measures (e.g., notifications to
the authorities and/or
surrounding communities) have
been made.
Maintenance strategies have
been developed for all equipment
and maintenance plans created
in Computerised Maintenance
Management System (CMMS),
Documentation and records,
including Process Safety
Information (PSI), have been
developed to reflect ‘as-built’
status.
Observed deviations from the
approved design have been
implemented in accordance with
CMS (Management of Change).

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PSSR for MOC
All requirements identified as
part of the MOC request
processing for permanent,
temporary, and emergency
changes have been
implemented, prior to startup.
Construction and equipment
installation is in accordance with
codes, standards, and design
specifications.
The modified equipment has
been tested, and certificates are
available.
Hazard identification and risk
assessment have been
conducted in accordance with
CMS (HSSE Risk Management)
and all recommendations have
been completed.
Initial, startup and normal
operating and maintenance
procedures have been updated
and are in place.
The need for additional or
updated training for all
concerned personnel has
been reviewed and has been
provided.
Emergency response plan(s)
have been reviewed and
where necessary have been
updated.
Any additional necessary HSSE
measures (e.g., notifications
to the authorities and/or
surrounding communities)
have been made.
Maintenance strategies have
been developed or updated
for all equipment and
maintenance plans created in
the CMMS.
Documentation and records,
including PSI, have been
updated to reflect ‘as-built’
status.
During the MOC process,
observed deviations from the
approved design have been
implemented in accordance with
CMS (Management of Change).

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PSSR For Turnaround Or Prolonged Maintenance Shutdown
The planned activities on all
equipment scheduled for overhaul,
maintenance or repair have been
successfully completed.
Any deferred maintenance,
inspection and testing activities
that are conducted during a
turnaround
Safety critical equipment has been
successfully tested.
Alarms and gauges have been
tested, and alarm lists have been
updated, where necessary.
Temporary structures, buildings and
trailers which are required are at an
appropriate safe distance away from
process safety hazards.
All relevant maintained equipment
notifications and workorders have
been updated to Technically
Completed
The overhaul, maintenance
or repair activities has not
negatively affected the
integrity of the equipment
itself, or adjacent
equipment.
Testing and calibration of
electrical equipment and
instrumentation has been
completed.
Documentation and records
have been updated to
reflect ‘as-built’ status.

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Timing of PSSR
The PSSR serves as the final check before energization, and is undertaken:
Condition 1: After pre-commissioning, when mechanical and electrical installations are
completed
Condition 2: Before commissioning, when systems are being energized.
The above applies to all PSSRs, regardless of whether is conducted as part of MOC, after a
turnaround, or as part of a capital expenditure project.

PSSR Process

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Overview
10 process steps to be undertaken to execute the PSSR are shown below:
Step 1: Selection
of PSSR team
Step 2: PSSR
Kick Off Meeting
Step 3:
Documentation
Review
Step 4: Facility
Walkdown
Step 5: PSSR
Close-out
Meeting and
Follow-up
Step 6:
Reporting of
PSSR Findings
Step 7: Follow-
up of PSSR
Findings
Step 8: Approval
for Start-up
Step 9:
Communication
of PSSR
outcome
Step 10:
Documentation
and Record
Keeping

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Step 1: Selection of PSSR team
• PSSR reviews are normally conducted using a multi-disciplinary team with the following
minimum requirements:
• PSSR Leader
• Operations representative
• Maintenance representative
• Project representative (for PSSR for CAPEX project)
• Commissioning representative
• Appropriate technical support representative
• HSE representative
• The PSSR Leader is appointed by the PSSR Owner. With input from the PSSR Owner, a PSSR
execution team (‘PSSR team’) is identified and established by the PSSR Leader.
• Depending on the scope of the PSSR, the participation of an independent competent third-party
may also be required. Should participation be deemed necessary, the role(s) and responsibilities
of the third-party shall be defined and agreed by the PSSR Leader and PSSR Owner.

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Step 2: PSSR kick-off meeting
• A kick-off session is organized by the PSSR Leader with the PSSR team members.
• The purpose of the meeting is to ensure understanding and familiarity with the PSSR
procedure and the PSSR checklist
• The meeting also serves to appropriately assign responsibilities for different aspects of
PSSR provided in the checklist.
• The availability of all required HSE, design, operational documents, etc. that are
required for and marked in the PSSR checklist shall be checked.
• Any additional information that is deemed necessary by the PSSR team to support the
review, shall be requested.

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Step 3: Documentation review
• This step together with the next step (‘facility walkdown’) form the core of the PSSR process.
• Guided by the checkpoints in the checklist and supported by interviews with the PSSR Owner
and his/her team members staff, the documentation gathered in the previous step is checked by
the PSSR team on whether it is:
• Available and accessible; and
• Fit for purpose (i.e., adequate, and current).
• Findings are recorded in the PSSR checklist by the PSSR Leader. The findings shall be
classified as described in later section of this presentation.

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Step 4: Facility walkdown
• A facility walkdown shall be undertaken to inspect the facility for operational readiness.
The entire PSSR team shall participate in the facility walkdown.
• Findings are recorded in the PSSR checklist by the PSSR Leader. The findings shall be
classified as described in the next section of this presentation.

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Step 5: PSSR close-out meeting and follow-up
• The findings collected in the previous steps are presented by the PSSR Leader and the
PSSR team in a close-out meeting with the PSSR Owner.
• The findings shall be discussed and agreed among the PSSR team and Owner.

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Step 6: Reporting of PSSR findings
• The scope, venue, timing, and findings of the PSSR review are documented by the PSSR
Leader into the PSSR checklist.
• All A-rated findings (i.e., to be addressed before energization) and B-rated findings (i.e.,
can be resolved after energization) are specified.
• B-rated findings shall be ranked and prioritized based on CMS (HSSE Risk Management).
• All the findings shall be computed into PSSR register (Appendix E) by the PSSR Leader

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Step 7: Follow-up of PSSR findings
• The PSSR Owner is responsible for ensuring any actions from the PSSR are followed up and
closed out through the PSSR register.
• PSSR Owner is responsible for tracking, follow-up, and close-out of any remaining PSSR
findings, after start-up.

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Step 8: Approval for start-up
• Directly before energization of the facility, the PSSR Owner approves start-up by signing off that all
A-rated findings have been closed and verifies that all B-rated findings (to be resolved after
energization) are up to date.
• This is recorded in the PSSR report which is integrated in the PSSR checklist.

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Step 9: Communication of PSSR outcome
All relevant parties to be informed about the PSSR and its
outcome and action items.

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Step 10: Documentation and record keeping
• The scope, venue and findings of the PSSR review are documented by the PSSR Leader in the
PSSR report. The completed report is registered and filed in the document control system for a
minimum of three years.
• PSSR register is a live document and used for tracking and monitoring A and B-rated findings.

Classification of Findings

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Classification of findings
• During the review process, a PSSR checklist point is met and acceptable for safe start-up if evidence
exists that, in the opinion of or as witnessed by the reviewer, has satisfied the specific requirement of
the checklist point.
• Verification findings (Punch List) that are not accepted are categorized as follows:
Finding category Description
A. Finding preventing
energization/ start-up
(start-up not allowed)
The risk exposure is too high to be tolerable for safe and effective start-up of the facility
reviewed. This is because the finding implies that:
• One or more safety critical barriers are absent or not effective and introduce a
major accident risk.
• A high-risk major accident scenario is likely to happen, which cannot be mitigated
with other engineering or administrative barriers.
• Legislative requirements not fulfilled.
B. Finding not preventing
energization/ start-up
(start-up allowed under
restrictive conditions)
The risk exposure is deemed acceptable for start-up but will require follow up.
• A barrier may be degraded, e.g., due to missing data, procedures, or training, but
this does not introduce an unacceptable major accident risk.
• A risk scenario could develop but has a low likelihood of occurring and if it did
would lead to low consequences. The risk can be managed by other existing
barriers/controls or by temporary measures being put in place.

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Roles & Responsibilities
Classified as Confidential Internal by SEC - )‫(داخلي‬ ‫مقيد‬ ‫مصنف‬ ‫للكهرباء‬ ‫السعودية‬ ‫الشركة‬

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Roles and responsibilities
A summary of the roles and responsibilities associated with PSSR are shown as below:
PSSR Owner PSSR Leader
PSSR Team Independent Third-Party

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PSSR Owner
The designated PSSR Owner:
• For capital expenditure projects is the Project Manager.
• For MOC is the Change Owner.
• For turnaround works is the Asset Owner.
The PSSR Owner is:
• Assigning a PSSR Leader and ensuring the PSSR Leader has resources to establish the PSSR
team.
• Arranging the PSSR after mechanical and electrical completion or completing turnaround scope of
the new / modified facility.
• Ensuring that the PSSR is conducted facility startup approval is obtained before the startup of any
new / modified facility.
• Following up with the concerned persons and verifying the completion of the action items in a timely
manner.

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PSSR Leader
• Selecting the PSSR team.
Scheduling the PSSR for the facility.
• Conducting the PSSR and leading the PSSR Team. This includes organizing and leading the PSSR kick-off
meeting and PSSR close-out meeting.· and ensuring that sufficient time is provided for conducting a
thorough PSSR review, i.e., that there is sufficient time is available for the team to:
 Review all items of the PSSR checklist.
 Conduct a walkthrough of the facility.
 Recording and classifying findings and defining actions during the documentation review and facility
walkthrough, with input from the PSSR team members. This includes:
 Ensuring that the PSSR checklist is completed and signed by all team members.
 Completing the PSSR corrective actions list and identifying the persons responsible for completing the action
items.
 Developing a PSSR report, documenting the scope, venue, timing, and findings of the PSSR review.
• Recording findings, classifying findings and defining actions during the documentation review and facility
walkdown.
• Developing a PSSR report, documenting the scope, venue, timing, and findings of the PSSR review.
Ensuring the completed PSSR report is registered and filed the document control system.

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PSSR Team
• Providing their expertise and participate effectively in the PSSR meetings and field walkthrough(s), under
the guidance of the PSSR Leader.
• Helping the PSSR Leader in identifying whether the facility is ready for energising, completing the checklist
and identifying gaps / corrections during the field walkthrough.
• Updating the PSSR checklist by adding necessary checklist items appropriate to the facility under
consideration using their expertise.

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Independent Third-Party
For a PSSR of a capital expenditure project:
• The participation of an independent third-party is optional, depending on the scope
of the project.
• Should participation be deemed necessary, then the role(s) and responsibilities of
the third-party shall be defined and agreed by the PSSR Leader and PSSR Owner

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