DOC.

SAFETY STANDARD DIVISION TATA STEEL EFFECTIVE

DATE
DOC. NO. TITLE PRE-START UP REVISION 0.0
SHEETS 1 OF 3 SAFETY DUE FOR
REVIEW REVISION
STANDARD
COMP. BY Ranadip Das SIGNED DATE
AUTH. BY Debashis Das SIGNED DATE

1.0 Purpose: To provide guideline for conducting Pre-Startup Safety Review, a final check for new and
modified equipment to confirm that all appropriate elements of process safety have been addressed
satisfactorily
2.0 Reference: Circular Number – VP S& FP / 132/2010 Dated: 2 September 2010.
Guidelines for Performing Effective Pre-Startup Safety Reviews- CCPS
3.0 Associated Hazards:
4.0 Applicability: This standard is applicable for all locations of Tata Steel India Limited
5.0 Responsibility: Agencies involved in execution (Operating and Maintenance departments,
Engineering & Projects)
6.0 Procedure:
6.1 Objective

The objective of PSSR Audit is to ensure that any changes that are made to a new or modified
facilities meet the original design or operating intent and no hazardous situation has been created
during construction & cold commissioning so that safe start-ups can be ensured.

A pre-startup safety review will be performed before the integrated trial of the system/equipment of
a new or significantly modified facility. The hazards identified and recommendations suggested
thereby must be implemented prior to startup.

Determining factors for PSSR is as follows:

A PSSR IS a must if the modifications to a facility require a change in the approved design/
equipment / technology of the process.

A PSSR IS NOT required for facilities that have been modified & no significant change other than
just Replacement-in-kind* was done.

MOC Connection
However, for all modified facilities, management of change (MOC) requirements must be satisfied
along with PSSR before energizing (If required as per MOC Procedure).

New Facilities
For new facilities, a process hazard analysis must be performed before energizing. The process
hazard analysis recommendations must be planned / implemented prior to startup.

*Replacement-in-kind (RIK): An item (equipment, material used in the process, procedures,

organizational structures, people, etc.) that meets the design specification, if one exists, for the item
it is replacing. This can be an identical replacement or any other alternative specifically provided
for in the design specification, as long as the alternative does not in any way adversely affect the
function or safety of the item or associated items.
DOC. SAFETY STANDARD DIVISION TATA STEEL EFFECTIVE
DATE
DOC. NO. TITLE PRE-START UP REVISION 0.0
SHEETS 2 OF 3 SAFETY DUE FOR
REVIEW REVISION
STANDARD
COMP. BY Ranadip Das SIGNED DATE
AUTH. BY Debashis Das SIGNED DATE

6.2 Scope

PSSR Audit team should review

1. Construction and equipment is in accordance with design specifications;
2. Safety, operating, maintenance, and emergency procedures are in place and are adequate.
3. For new facilities, a process hazard analysis has been performed and recommendations have
been resolved or implemented before startup; and modified facilities meet the requirements
specified in Management of Change.
4. The construction and equipment has been checked for conformance with design specifications
and applicable codes and standards.
5. Applicable process safety information has been developed or updated as necessary to reflect the
new/modified process.
6. Plant wide safe work procedures are adequate considering the new/modified process conditions.
7. Training of each employee involved in operating and /or maintaining the process has been
completed and documented.

6.3 PSSR Audit Team

Head/ Sr.Manager /Manager, Operation must be the leader of PSSR team and there should be
members from Engineering (if job has been executed by them), Operation & Maintenance. Safety
Professional of owner department should also be a part of the team and he/she should guide the
PSSR Team in conducting the internal audit.

6.4 Audit Procedure

The PSSR Team should fill up Form No.1 (Annexure-1) themselves based on internal assessment &
send it to Head Process Safety with request for Audit by Central Process Safety Team.
PSSR Audit should be carried out through multidisciplinary team. The composition of the team
members shall be of Safety Professionals and Fire Safety Professional or experts.
Head Process Safety will be the overall coordinator of the audit team & he will be responsible for
the selection of the audit team.
All the auditors shall be trained on the audit skills & assessment.

Central safety Team will conduct the document audit and site audit within 7 days of submission of
FormNo.1. The auditors shall check the compliance related with each point through documental
evidence/Physical verification (wherever necessary). Non Compliances shall be recorded in separate
sheet. The audit should be done in presence of PSSR Team.

Findings of PSSR Audit report to be prepared in Form No.2 (Annexure-2) & sent to the team leader
with a copy to Chief, Safety & Ergonomics within Seven days.

After taking action for all the Non Compliances the department with filled up FormNo.2 will
approach Head, Process Safety for authorization.
After verification by audit team Head/ Sr.Manager , Process Safety/ will give feedback to Chief,
Safety & Ergonomics about the compliance.
If any major non-compliance is found during the audit or before the energization, Chief safety &
ergonomics has right to hold clearance for energization.
DOC. SAFETY STANDARD DIVISION TATA STEEL EFFECTIVE
DATE
DOC. NO. TITLE PRE-START UP REVISION 0.0
SHEETS 3 OF 3 SAFETY DUE FOR
REVIEW REVISION
STANDARD
COMP. BY Ranadip Das SIGNED DATE
AUTH. BY Debashis Das SIGNED DATE

At his discretion he might allow energizing with minor non conformities with specific instruction to
close them within a specific time.
Central Audit team will give approval for energization (Form in Annexure-3) based on the audit
report & compliance report send by the department with consent of Chief Safety & Ergonomics.
Only the Vice President, Safety or Chief, Safety & Ergonomics shall have authority to exercise
judgment in rejecting any of the recommendations given in audit report.
A copy of Authorization certificate to be maintained by Head process Safety for record keeping.

Note- In case of PSSR for modified facilities MOC Procedure should be followed and RFC
(Request for change) document should be submitted along with Form1.