Prepared and arranged by: Dr. Amin Padash, HSEQ Coach, President of the Iranian Scientific Association of Health, Safety and Environmental Management and Engineering (HSEME)

A PSSR is a systematic process performed before the startup of any new, modified, or repaired facility, equipment, or system to ensure operational safety and compliance. It acts as a final verification step, confirming that all elements—both physical (hardware) and procedural (training, documentation, safety systems)—are in place and functioning properly to prevent incidents.

PSSR is often mandated by industry standards, such as:

• OSHA's Process Safety Management (PSM) Standard (29 CFR 1910.119)
• API RP 75 for offshore drilling and production.
• ISO 45001 for occupational health and safety management.

Detailed Steps in a PSSR Process

1. Scope Definition:
• Clearly identify the systems, processes, or equipment to be reviewed.
• Ensure alignment with the purpose (e.g., new project, equipment upgrade, or modification).
2. Checklist Development:
• Prepare detailed checklists to guide the review process, including:
• Mechanical integrity.
• Instrumentation and control systems.
• Operational procedures.
• Emergency shutdown systems.
• Training records.
3. Documentation Review:
• Verify that key documents are available, accurate, and complete:
• Piping and instrumentation diagrams (P&IDs).
• Process Hazard Analysis (PHA) or HAZOP findings.
• Operating procedures.
• Maintenance records and schedules.
4. Field Inspections:
• Inspect the physical installation of equipment to confirm compliance with design specifications.
• Ensure proper installation of safety systems like alarms, interlocks, and pressure relief devices.
5. Testing of Equipment and Systems:
• Conduct operational readiness testing, including:
• Functionality of fire and gas detection systems.
• Startup and shutdown sequences.
• Leak tests for pipelines and tanks.
• Calibration of instruments.
6. Personnel Training and Competency:
• Confirm that all involved personnel (operators, maintenance staff, contractors) are trained and familiar with:
• Standard operating procedures (SOPs).
• Emergency procedures.
• New or modified equipment.
7. Action Item Closure:
• Address any deficiencies or incomplete tasks identified during the PSSR process.
• All issues must be resolved before granting permission to start operations.
8. Approval and Authorization:
• Obtain sign-off from all relevant stakeholders (safety team, engineering, operations, management) to proceed with the startup.

Role of PSSR in High-Risk Industries

1. Drilling Industry:
• Drilling rigs operate in dynamic and hazardous environments. A PSSR ensures:
• Blowout preventers (BOPs) are properly installed and functional.
• Well control systems are tested.
• Rig floor equipment (e.g., tongs, top drives) is inspected and safe for use.
• Emergency evacuation procedures are in place for offshore or remote rigs.

Example:

• Before initiating a deepwater drilling operation, the PSSR ensures that the BOP stack is pressure-tested to prevent blowouts, and drilling fluids are adequately circulated to stabilize the well.
1. Rig Operations:
• Mobile rigs require PSSR during each relocation or after significant maintenance:
• Inspect rig structure stability during installation.
• Verify power generation systems are operating correctly.
• Test hoisting systems and cranes for safe operation.

Example:

• A jack-up rig being installed offshore undergoes PSSR to ensure proper leg deployment and secure anchoring before drilling starts.
1. Petrochemical Industry:
• In petrochemical plants, where flammable and toxic chemicals are processed, PSSR ensures:
• Proper integration of process controls, safety interlocks, and alarm systems.
• Leak tests of high-pressure pipelines and storage tanks.
• Firefighting systems (e.g., foam suppression, water deluge systems) are functional.

Example:

• After a major turnaround in a refinery, PSSR confirms that pressure relief valves are recalibrated and functional to prevent overpressure events during startup.

Challenges and Solutions in Conducting PSSR

Challenges:

1. Complexity of Operations:
• Drilling rigs and petrochemical plants involve numerous interdependent systems, making it difficult to identify all potential risks.
2. Time Constraints:
• Delayed startups are costly, leading to pressure to complete the PSSR quickly, which may result in overlooking critical safety issues.
3. Inadequate Training:
• Personnel may lack the necessary expertise to evaluate the safety and operational readiness of specialized equipment.
4. Documentation Gaps:
• Missing or outdated drawings, procedures, or inspection records can hinder the review process.

Solutions:

1. Use standardized checklists tailored to specific equipment and systems.
2. Invest in personnel training to ensure competent PSSR teams.
3. Leverage digital tools for documentation management and tracking action items.
4. Conduct mock reviews to identify potential gaps before formal PSSR.

Benefits of PSSR

1. Prevents Accidents and Downtime:
• Identifies and mitigates hazards, reducing the likelihood of incidents like fires, explosions, or equipment failures.
2. Regulatory Compliance:
• Ensures adherence to OSHA, API, and ISO standards, avoiding fines and legal repercussions.
3. Improved Operational Efficiency:
• Confirms that equipment is ready and functioning as designed, reducing startup delays and operational disruptions.
4. Enhances Safety Culture:
• Involves employees in safety reviews, promoting a proactive approach to identifying and addressing risks.
5. Protects Assets and Reputation:
• Safeguards expensive equipment, minimizes environmental impact, and maintains stakeholder trust.

The Pre-Startup Safety Review (PSSR) is a cornerstone of risk management in high-risk industries like drilling, rig operations, and petrochemicals. It ensures that safety systems, processes, and personnel are prepared before operations begin. By conducting thorough inspections, testing equipment, and addressing deficiencies, PSSR prevents accidents, ensures regulatory compliance, and supports safe and efficient operations.