(III) PSSR PROCEDURE (Rev00) PDF

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SAFETY HEALTH AND ENVIRONMENT
PROCEDURE
PRE-START UP SAFETY REVIEW
PROCEDURE
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I.
PURPOSE
Establish procedure as basic guidance team to do PSSR in the Tuban Petrochemical
complex.
II.
OBJECTIVE :
To ensure that facilities are safe for starting up after completion of new project
construction, modifications to existing facilities or after completion of plant turnaround
activities.
To ensure new plant or modifications to existing facilities are reliable and comply with
applicable Policies, Guidelines, Standards and Statutory Requirements.
III. SCOPE
The pre-startup safety review shall be conducted after the following activities:
o
o
o
o
o
After completion of new plant or modification to the plant.

After unit turnarounds. (PSSR shall be conducted
separately for each process unit).
After modification to existing plant which necessitates changes in the process safety
information such as:
P&IDs / PFDs
MSDSs for chemicals used in the modified process
Safety interlocks / Safety Critical Devices
Construction materials
Process chemistry
Inventory quantity and types of hazardous chemicals/materials
Operating parameters outside the design envelop/limits
Fire protection systems
Operating procedures
Unit restart after an outage of more than 1 month.
After partial shutdown of a unit for inspection / repair work. Partial shutdown shall
mean the shutting down of at least one type of the following equipment:
Heater
Tower/column
Tankage
Desalter
Boilers
CTGs
Sour water stripper
Incinerator
N2 Plant
Compressors
IV. DEFINITION
C:\Data\My Data\FSE File\SHE PROCEDURE AND INSTRUCTION\PT TPPI FIRE AND SAFETY PROCEDURE\PT TPPI SAFETY PROCEDURES\( IV ) LOSS PREVENTION PROCEDURE\(III) PSSR
PROCEDURE (rev00).doc
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Pre-start up safety review is a safety review takes place before any highly hazardous
chemical is introduced into a process. Process Safety Management, therefore, requires the
employer to perform a pre-startup safety review for new facilities and for modified facilities
when the modification is significant enough to require a change in the process safety
information.
V.
PROCEDURE
5.1 Start-up Planning and Preparation
The startup team shall focus, among other requirements, on the following:
Preparation of operating manuals/procedures or revisions to existing
operating
Manuals / procedures, if there are modifications to the plant facilities.
Preparation on new equipment for startup.
Checkout of new facilities prior to startup
Training of the operators/engineers for normal and emergency operations.
5.2 Pre-startup safety Review
Prior to startup of the plant, the Operations Day-work Supervisor or PSSR Leader shall
coordinate with the Pre-Startup Safety Review Team, comprising of representatives
from the relevant functions to conduct a pre-startup safety review. Relevant function
shall mean:
(i) For new construction/facility modification, those functions involved in the design,
construction, operation, maintenance, and safety of the new or modified facility.
(ii) For re-startup of an existing plant, those functions involved in the
maintenance, operation, inspection and safety of the plant.
The pre-startup checklist provided in Appendix-2 is used to facilitate the review process.
The team may include other relevant checks / comments in the comment section of the
checklist. Members have to assure themselves that:
Construction is in accordance to specifications and all legal or permit
requirements are complied with.
All engineering design drawings and process information are updated and
available for operating the plant.
Adequate Safety & MSDS, Environmental, Emergency shutdown, Operations and
Maintenance procedures are in place.
Safety critical devices (Safety Interlocks/PSVs) are tested to be functioning or legal
PSV certificate available.
Fire protection systems are adequate and operationally ready.
All recommendations from risk assessment (or design HAZOP) and field quality
inspections which are critical to safe operations of the plant have been addressed
and required actions taken.
Process Control and monitoring systems required for operations are ready.
Any additional training of operations and maintenance personnel on the new
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system has been completed.

Upon the completion of the pre-startup safety review, the team will initial on the Pre-Start
up Safety Sign-Off Form (Appendix 1) if they are satisfied that the plant is ready for a
safe startup.
The Day Superintendent/Supervisor or PSSR leader shall review the outcome of the
pre-start up safety review with the TPPI Team Manager who will then determine
whether to authorize start up of the plant. Any applicable items not completed and any
outstanding issues generated from the review shall be addressed and action taken by
the respective work groups.
VI.
RESPONSIBLE AND ACCOUNTABLE RESOURCES

General Operations Manager:
o Accountable for the implementation of this procedure through his subordinates.
Area Manager:
o Appoints a PSSR Team comprising of representatives from the relevant functions
(e.g. Operations, Engineering, Maintenance (Static, Rotating, Piping), Electrical,
Instrument, QC, Civil, SH&E and Others as necessary to conduct the PSSR).
o Ensures that the pre-startup safety reviews are conducted and checklists signedoff by the relevant team members before commencing startup activities.
Operations Day Superintendent /supervisor and or the appointed PSSR Team
Leader (PSM)
o Coordinates and lead the pre-startup safety reviews.
VII. DOCUMENTATION
The completed document shall be maintained by Operations Supervisors for a period of 3
months.
VIII.APPENDIX
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8.1 Appendix-1
PRE-START UP SAFETY REVIEW SIGN-OFF FORM
PSSR Title/Operating Unit:
__________________________________________
REVIEW TEAM MEMBERS CHECK OUT
We have made the pre-start up safety review and with the best of our knowledge, the
plant is safe for start up.
YES / NO / NA
Name
Signature
Date
OPERATION
___ /___ / ___
_____________
________
______
ENGINEERING
___ /___ / ___
_____________
________
______
MECH./STA/PIPING
___ /___ / ___
_____________
________
______
ELECTRICAL
___ /___ / ___
_____________
________
______
INSTRUMENT
___ /___ / ___
_____________
________
______
Q/C
___ /___ / ___
_____________
________
______
CIVIL
___ /___ / ___
_____________
________
______
SHE
___ /___ / ___
_____________
________
______
_________________ ___ /___ / ___
_____________
________
______
_________________ ___ /___ / ___
_____________
________
______
OTHERS (specify)
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8.2 Appendix-2
OPERATION REVIEW CHECK LIST
YES / NO / NA
Name/Sign
1.
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____

____ / ___ / ____
___________
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
Are the operating and emergency

procedures updated and current?
2.a Are operators trained to startup,
operate and shutdown the
new/modified unit safely?
2.b. Are operators also trained to respond
to utility failures including emergency
shutdowns.
3. Have temporary facilities like hydro testing
stubs and drain points, temporary blinds, etc
that are not part of the startup and operation
of the plant has been removed?
4. Are the equipment / pipeline insulation
checked to ensure that they are
NOT OIL SOAKED?
5 a. Are all shutdown blinds removed
according to established blind list?
5.b Are all normal process operating blinds
re-installed?
6 a. Are pipe drain/vent valves closed and
plugged/capped or end blinded?
6.b Are vessels drain/vent valves closed and
plugged/capped or end blinded?
7. Are normally operating PSV block valves
carsealed open(Chain Pad Lock), and
standby one carsealed (CPL) closed?
8. Are the sewers clear of trash and
construction waste clear?
9. Are Process Hazard Analysis (HAZOP)
Re-commendations resolved?
10. Are all block valves in the pressure
Relief valve to flare loop car-sealed opened?
11. Have all vessels checked and boxed up?
12. Are process graphics updated/available
in the DCS ?
13. Are new Safety Critical Devices
included into the unit ESD list for planned
testing and maintenance ?
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OPERATION REVIEW CHECK LIST(Cont)

Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Operations Coordinator: ________________________________________
Signature: ______________________
Date
: _______________
(Note: Applicable items not completed prior to start-up must be followed up and completed
within a set time frame)
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ENGINEERING REVIEW CHECK LIST
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YES / NO / NA
Are the items that are associated with the

safe startup, shutdown and operation of the
facilities completed?
(Operations to advice the critical equipment) ____ / ___ / ____
2. Are the equipment and piping constructed
according to design specification?
____ / ___ / ____
3. Are the materials of construction according
to the designed specifications?
____ / ___ / ____
4. Has the use of carbon steel materials
operating at >= 260 deg C been discussed
and approve with QC group?
____ / ___ / ____
5. Are new tie-ins pressure tested and weld
joints inspected according to ASME or
associate established standards?
____ / ___ / ____
6. Are new load bearing structures fire proofed
according to I.P. standards?
____ / ___ / ____
7. Are flanges joints checked for correct
gaskets and bolts?
____ / ___ / ____
8. Are new Safety Critical Devices
(interlock systems) calibrated, tested and
Function tested?
lf no, attach completed list of status.
____ / ___ / ____
9. Are new additions of pressure relief
devices bench tested/certified and the total
relief piping sizing checked as per P&ID?
____ / ___ / ____
10. Are new chemicals/catalyst MSDS made available?____ / ___ / ____
11. Has concerns arising from design HAZOP
has been resolved ?
____ / ___ / ____
12. Are the facilities consistent with
the intended process design?
____ / ___ / ____
Name/Sign
1.
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
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_____________________________________________________________________
ENGINEERING REVIEW CHECK LIST (Cont)

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Engineering Coordinator: ________________________________________
Signature: ______________________
Date
: _______________
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MECH/STA/PIPING REVIEW CHECK LIST YES / NO / NA

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Are the testing/checks on critical equipment,

including Safety Critical Devices associated
with the safe startup, shutdown and operation of
the facilities completed? (Operations to identify
these critical equipment/devices).
Are the equipment and piping constructed
according to design specifications?
Are modification design and construction
information available for updating?
Are the materials of construction according to
the job designed specifications?
Are new tie-ins pressure tested and weld joints
inspected according to ASME/established
standards?
Are the load bearing structures fire proofed
according to I.P. standards?
Are flanges joints checked for correct gaskets
and bolts tightening?
Are QC recommendations that are critical for
safe operation completed?
Have temporary facilities like hydrotesting stubs
and drain points, temporary blinds, etc that are
not part of the start-up and operation of the plant
been removed?
Piping system analyzed for stress and
movement due to thermal expansion?
Pipe flushing all piping has been made?
Pipe support completed?
Isolation and drained system for maintenance
are sufficient?
Piping and equipment labeling clear?
All vent line direction to safe location?
Are vessel, column, heater has been inspected
before box up?
Have all rotating equipment has been
mechanical run tested?
Name/Sign
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____

____ / ___ / ____
___________
___________
____ / ___ / ____

____ / ___ / ____
____ / ___ / ____
___________
___________
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
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MECH/STA/PIPING REVIEW CHECK LIST(cont)

Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Maintenance Coordinator: ________________________________________
Signature: ______________________
Date
: _______________
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ELECTRICAL REVIEW CHECK LIST

1.
2.
3.
4.
5.
6.
7.
8.
9.
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YES / NO / NA
Grounding system has been measure and

meet with specification for each equipment? ____ / ___ / ____
Electrical equipment comply with proper
electrical hazards classification?
____ / ___ / ____
Are electrical power disconnects has been
install lock out tagging system?
____ / ___ / ____
Label all START-STOP has been installed?
____ / ___ / ____
Lightning system has been install properly?
____ / ___ / ____
All Lighting system has been illumination
tested and additional required?
____ / ___ / ____
Safety sign for electrical apparatus/panel has
been installed?
____ / ___ / ____
Cable tray route safe from hazardous material? ____ / ___ / ____
Are cathodic protection has been install and
____ / ___ / ____
tested?
Name/Sign
___________
___________
___________
___________
___________
___________
___________
___________
___________
Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Electrical Coordinator: ________________________________________
Signature: ______________________
Date
: _______________
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INSTRUMENT REVIEW CHECK LIST

1.
YES / NO / NA
Name/Sign
Are All field instrument (transmitter, pressure
Switch, dumper, CV etc) has been calibration and

Function tested?
____ / ___ / ____
2. Are DCS communication has been
function tested?
____ / ___ / ____
3. Are the Safety Interlock systems calibrated,
tested and functional?
____ / ___ / ____
4. Are emergency safety valves / shutdown systems
tested to be functional?
____ / ___ / ____
5. Are detectors / alarms calibrated and
tested to be functional?
List of detectors / alarms
H2S detectors / alarms / beacons
____ / ___ / ____
Hydrocarbon detectors
____ / ___ / ____
Flame/fire Detectors
____ / ___ / ____
H2 detectors
____ / ___ / ____
Cl2 detectors
____ / ___ / ____
6. Are control instrument, interlock system
fail safe?
____ / ___ / ____
7. Communication devices (radio,
system etc) are comply IS standard?
____ / ___ / ____
8. Are control label clearly identified?
____ / ___ / ____
9. Tubing run safe or protected from hazardous
materials?
____ / ___ / ____
10. Are Instrument management change procedure
available in CCB?
____ / ___ / ____
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
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_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Instrument Coordinator: ________________________________________
Signature: ______________________
Date
: _______________
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QC REVIEW CHECK LIST

1.
2.
3.
ls the condition and thickness of the following

equipment satisfactory for safe operation?
(Satisfactory thickness is based on original
as-built thickness and
corrosion allowances) of:
Towers
Vessels
Heaters
Exchangers
Piping (Selected)
Storage tanks
Are PSV pre-pop tested and reset
to their set pressures and certified
by DEPNAKER?
Has Ministry of Manpower (DEPNAKER)
inspected statutory equipment where
required (tanks, vessel, column etc)?
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YES / NO / NA
Name/Sign
____ / ___ / ____

____ / ___ / ____
____ / ___ / ____
____ / ___ / ____
____ / ___ / ____
____ / ___ / ____
___________
___________
___________
___________
___________
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
QC Coordinator: ________________________________________
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Signature: ______________________
Date
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: _______________
CIVIL/STRUCTURE REVIEW CHECK LIST YES / NO / NA

Have plant standards been followed for
stairways, platforms, ramps & fixed ladders? ____ / ___ / ____
2. Is the head clearance in walkway and
working areas adequate?
____ / ___ / ____
3. Are platforms and sufficient clearance
provided around equipment for maintenance
and operations access safely?
____ / ___ / ____
4. Are sufficient general exit facilities &
escape routes available, including alternate
means of escape from roof?
____ / ___ / ____
5. Do clearances around access, where loading
or unloading facilities are installed, comply with
access specification?
____ / ___ / ____
6. Are fireproofing structural steel has been
Installed as per requirement?
____ / ___ / ____
7. Are areas properly drained?
____ / ___ / ____
8. Are access ways provided?
____ / ___ / ____
9. Are fire walls, dikes and special guardrails
installed?
____ / ___ / ____
10. Are hazardous underground line
obstructions/blocked?
____ / ___ / ____
Name/Sign
1.
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
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_____________________________________________________________________
CIVIL/STRUCTURE Coordinator: ________________________________________
Signature: ______________________
Date
: _______________
SHE REVIEW CHECK LIST

1.
2.
3.
4.
5.
6.
7.
8.
9.
Are the following safety and fire protection

equipment installed and tested to be functional?
Fire extinguishers
Self Contain Breathing Apparatus
Personal Protective Equipment (PPE)
Hazard Warning Signs
Are the following fixed safety and fire
protection equipments installed and tested
to be functional? For existing equipment,
are they tested/inspected per schedule
by Operations and issues resolved?
Hydrants and monitor
Water Spray system
Safety showers and eyewash
Emergency Lighting
Has the Fire Safety Equipment Listing been
revised and updated to reflect new equipment?
Have relevant material safety data sheets been
updated and made available?
Fire fighting equipment and routes accessible?
Have plans been made for the containment
and disposal of the discharges from relieving
devices?
Are there written procedures covering
emergency action for all leaks or spill?
What is waste storage system for:
Labeled with clear label (if used
empty drums)
Good containers compatible with materials
Spill containment and leak segregated
Are tank farms, storage areas
(including drums), loading and unloading
areas paved and dike?
YES / NO / NA
Name/Sign
____ / ___ / ____

____ / ___ / ____
____ / ___ / ____
____ / ___ / ____
___________
___________
___________
___________
____ / ___ / ____

____ / ___ / ____
____ / ___ / ____
____ / ___ / ____
___________
___________
___________
___________
____ / ___ / ____
___________
____ / ___ / ____

____ / ___ / ____
___________
___________
____ / ___ / ____
___________
____ / ___ / ____
___________
____ / ___ / ____

____ / ___ / ____
____ / ___ / ____
___________
___________
___________
____ / ___ / ____
___________
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10. Are drainage systems adequate to handle
worst case flows and flooding test has
been done?
11. Are storm water-potentially contaminated
water, OWS
well segregated?
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____ / ___ / ____
___________
____ / ___ / ____
___________
SHE REVIEW CHECK LIST (Cont)

Comments:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
SHE Coordinator: ________________________________________
Signature: ______________________
Date
: _______________

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After completion of new plant or modification to the plant.

system has been completed.

RESPONSIBLE AND ACCOUNTABLE RESOURCES

___ /___ / ___

___ /___ / ___

___ /___ / ___

___ /___ / ___

___ /___ / ___

___ /___ / ___

___ /___ / ___

___ /___ / ___

_________________ ___ /___ / ___

_________________ ___ /___ / ___

OPERATION REVIEW CHECK LIST

____ / ___ / ____

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Are the operating and emergency

OPERATION REVIEW CHECK LIST(Cont)

ENGINEERING REVIEW CHECK LIST

Are the items that are associated with the

ENGINEERING REVIEW CHECK LIST (Cont)

MECH/STA/PIPING REVIEW CHECK LIST YES / NO / NA

Are the testing/checks on critical equipment,

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

MECH/STA/PIPING REVIEW CHECK LIST(cont)

ELECTRICAL REVIEW CHECK LIST

Grounding system has been measure and

INSTRUMENT REVIEW CHECK LIST

Are All field instrument (transmitter, pressure

Switch, dumper, CV etc) has been calibration and

QC REVIEW CHECK LIST

ls the condition and thickness of the following

____ / ___ / ____

____ / ___ / ____

____ / ___ / ____

CIVIL/STRUCTURE REVIEW CHECK LIST YES / NO / NA

SHE REVIEW CHECK LIST

Are the following safety and fire protection

____ / ___ / ____

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