Pre-startup safety reviews (PSSRs) are an essential final step when bringing an updated or new process online, yet it can be easy to omit key PSSR components due to time or budget pressures.
An effective change management system such as Meridian can increase visibility of scope and ensure a successful PSSR process, but for optimal success it requires having the appropriate team members.
Process Safety Review (PSR)
Before any new or updated process is introduced into operations, its safety must first be thoroughly assessed through an impartial, open process Safety Review (PSR). The PSR must not only focus on existing processes but should cover more broad aspects. Review should cover both organisational and management system elements as well as technical ones, with special attention paid to so-called’soft’ issues like leadership and safety management which have proven themselves as having significant effects on overall risk levels. A PSR should take into account lessons learned from recent major incidents across industries and the economy as a whole, including nuclear. Furthermore, it should anticipate potential changes to technology or effects of aging on facilities over the coming decade.
The licensee should devise their own PSR, though it must meet ONR’s expectations as set out in this guidance and international best practice. A typical PSR will typically consist of a table with key information for each area of their facility highlighted and an outline program of work to implement reasonably practicable improvements that enhance safety.
LC15 or equivalent legislation requires reviews on plants subject to this legislation, so any review conducted must reflect that. In general, reviews will follow a schedule set forth by regulatory authorities for other facilities.
As part of its review process, the PSR should evaluate whether any existing procedures or equipment require revision or modification to enhance safety. Any recommendations included within it should be implemented, where possible.
Pre-Startup Safety Reviews are a key part of PSRs, and their PSPM should ensure all requirements within this aspect are properly managed. This usually means selecting an effective team to lead this review and providing employees with necessary documentation and training prior to beginning or restarting any covered process – often achieved through effective change control and document management processes.
Process Equipment Evaluation (PED)
The PED is an internationally recognized standard that outlines design and manufacturing criteria for pressure equipment with maximum allowable pressures exceeding 0.5 bar, along with compliance assessment procedures and essential safety requirements. Adherence to this standard will ensure your company abides by high operational standards, possibly protecting you from legal liabilities or financial penalties while improving both reputation and competitiveness.
To remain compliant with the PED, your company must undergo an intensive inspection and testing process by an EU-accredited inspector. This may involve inspecting materials used to manufacture your equipment as well as manufacturing processes that adhere to directive standards. Working with experts who are knowledgeable of its nuances is key and can customize services specifically to your business needs is ideal.
PED compliance not only allows your products to meet quality standards, but it is also key for businesses that wish to expand overseas. Furthermore, it demonstrates your dedication to maintaining high operational standards which may attract customers while improving brand image.
Step one of determining your equipment category involves identifying its type, fluid phase and fluid group. Pressure equipment like vessels, steam generators and piping is typically classified into categories 1, 2, 3 and 4, where category 4 poses the greatest risks.
After you have identified the equipment’s category, the next step should be deciding upon its conformity assessment modules. These depend on both its category and manufacturer’s own quality systems – for instance a category 2 product might require audit of manufacturing process as well as review of Technical Construction File (TCF), while category 3 products might necessitate in-depth inspection of pressure vessels while for category 4 devices an in-depth investigation will need to take place into design calculations of equipment design and calculations.
Pressure Equipment Evaluation (PEE)
Pressure equipment includes vessels, piping, safety accessories and other components with maximum allowable operating pressures of at least 0.5 bar. The Pressure Equipment Directive (PED) establishes standards for designing and fabricating these systems to comply with European safety standards and categorising them from categories I to IV depending on risk level. Businesses who manufacture, sell or operate pressure equipment should abide by this directive to ensure compliance with European safety standards while remaining compliant with its guidelines for testing and inspections to comply with PED guidelines.
Pre-Startup Safety Reviews (PSSRs) provide an in-depth evaluation of facilities and equipment prior to being put into operation, usually conducted by engineering, operations, maintenance and lubrication departments of plants or businesses. Their purpose is to make sure any new installation or modification meets design expectations before becoming active in operation.
Conducting a PSSR can help your business avoid fines and avoid accidents that could harm its employees or customers, while protecting it from possible lawsuits that result from equipment malfunction or failure. If you’re unfamiliar with regulations, consulting an expert is often best in order to avoid mistakes and maintain compliance.
PED experts possess an in-depth knowledge of this directive and will assist in helping you understand how it applies to your equipment and systems. Furthermore, they’ll keep you abreast of any changes that could impact your business and offer advice on staying compliant.
PSSR and PED regulations are both vital components of safe plant operation. Each has their own set of responsibilities and targets; both aim to ensure the equipment and operations used by plants in their work environments remain safe for workplace usage. To make the most of these reviews and ensure they fulfill their purpose effectively, engineering teams should include professionals of appropriate qualifications on their teams – this will save money in terms of expensive repairs while meeting legal obligations in terms of meeting PSSR or PED obligations.
Pre-Startup Safety Review (PSSR)
Pre-startup safety reviews involve conducting an examination of facilities and equipment before their operation begins, taking a comprehensive view that includes not only equipment itself but also procedures and training related to its operation. A multidisciplinary team from engineering, maintenance, operations, FI&R compliance departments as well as compliance departments should conduct this review to ensure all perspectives are considered.
For any PSSR to be successful, all aspects of its process must be covered. This includes making sure that any change or modification implemented complies with the original design and operating intent; that all required safety workshops (HAZOP study, model review and hazard analysis) have taken place; and that documentation for each step in the new or modified process are ready and waiting when it goes live.
PSSRs are typically conducted by either the MOC Originator (in the case of new facilities and processes) or PSPM (for existing processes). A standard review checklist will be distributed to Team Leader, who is then responsible for scheduling, selecting team members and documenting this review process.
Team members should be selected based on their knowledge, experience and responsibilities in the relevant area. For instance, it should include someone from the engineering department involved with designing and building the process, representatives from FI&R/maintenance departments as well as safety personnel; additionally QA and compliance should also be present to verify all documents comply with relevant regulations.
Executing a Process Safety and Safety Review is extremely essential to protecting your business against costly penalties. An unsafe condition occurring during startup and operation of process equipment could have devastating repercussions for your organization, from fines to losing valuable clients and even plant shutdown. By taking the time and care necessary for conducting a PSSR, it will help avoid these problems and protect it against unnecessary expenses.