900 Oil and Gas Safety Management

14 PSM Elements

7. Pre-Startup Safety Review (PSSR)

A Pre-Startup Safety Review (PSSR) is a required safety check performed before introducing hazardous chemicals into newly constructed or significantly modified equipment.

Its purpose is to verify that all aspects of the facility are prepared for safe operation. This includes confirming that the installation matches the approved design, equipment is properly installed and tested, and all safety systems—such as alarms, interlocks, relief devices, and shutdown systems—are functioning as intended.

The PSSR also confirms that operating procedures have been created or updated, that any recommendations from the Process Hazard Analysis (PHA) related to the modification have been resolved, and that employees have received training on the new or revised procedures. Documentation such as P&IDs, operating limits, and maintenance requirements must be complete and current before startup authorization is granted.

In the oil and gas industry, PSSRs are essential because startups and restarts are among the most hazardous operating phases. Whether adding a fractionation column, upgrading a compressor, installing new pumps, modifying pipeline routing, or expanding storage capacity, even small discrepancies between design and installation can create major hazards such as overpressure, vapor releases, or ignition risks. Conducting a thorough PSSR ensures that any construction errors, undocumented changes, or missing safeguards are identified and corrected before the system goes online.

Examples: Before restarting a modified LNG vaporizer, confirm blast-resistant control room upgrades and updated procedures for ammonia releases.

8. Mechanical Integrity (MI)

Facilities must establish written procedures to ensure critical process equipment is properly designed, inspected, tested, repaired, and maintained. Covered equipment includes tanks, pressure vessels, piping and valves, pumps, relief systems, shutdown systems, and controls. Storage facilities typically have fewer components than large plants, but MI requirements remain equally important.

A mechanical integrity program begins with listing all equipment and using manufacturer recommendations, applicable codes, or industry best practices for inspections and tests. All work must follow RAGAGEP, and inspection frequency must meet or exceed these standards. Employers should seek expert guidance if unfamiliar with RAGAGEP and may also consult local fire officials.

Maintenance personnel must be trained on the process, hazards, and safe work procedures, especially when contractors perform MI tasks. All inspections and tests must be documented, and deficiencies must be corrected before use or managed safely with a Management of Change (MOC) review if operation continues temporarily.

Quality assurance is also required to ensure new equipment is suitable for its intended use and that replacement parts and materials are compatible with design specifications.

Examples: In refineries, inspect piping for corrosion under insulation every 5 years, resolving anomalous thickness data; deficiencies like leaking elbows in H₂S lines or undersized relief valves in alkylation units must be corrected promptly.

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