Guidelines for Performing Effective Pre–Startup Safety Reviews +CD

List of Tables.
<p>List of Figures.</p>
<p>Items on the CD Accompanying This Book.</p>
<p>Acronyms and abbreviations.</p>
<p>Glossary.</p>
<p>Acknowledgements.</p>
<p>Preface.</p>
<p>1. Introduction.</p>
<p>1.1 What are the Benefits of Performing Pre–startup Safety Reviews?</p>
<p>1.2 How PSSR Relates to Other Process Safety Elements.</p>
<p>1.3 An Overview of the Risk–based Approach to PSSR.</p>
<p>1.4 What is the Scope of a PSSR? Process Safety, Environmental, Quality and Personnel Safety Considerations.</p>
<p>1.5 This Guideline s Audience.</p>
<p>1.6 How to use this Guideline.</p>
<p>1.7 References.</p>
<p>2. What Is a Pre–Startup Safety Review?</p>
<p>2.1 The Basics of Pre–startup Safety Review.</p>
<p>2.1.1 Some Common Steps for Performing PSSR.</p>
<p>2.2 What is a Risk–based Approach to PSSR?</p>
<p>2.3 The Role of Training in Pre–startup Safety Review.</p>
<p>2.3.1 Training Team Leaders and Members.</p>
<p>2.3.2 Training Managers and the Remaining Workforce.</p>
<p>2.4 Scheduling Considerations.</p>
<p>2.4.1 Capital Projects.</p>
<p>2.4.2 Changes to Operating Facilities.</p>
<p>2.4.3 Temporary Changes.</p>
<p>2.4.4 Restarting a Mothballed Process.</p>
<p>2.4.5 Post–turnaround Startup.</p>
<p>2.4.6 Routine Maintenance.</p>
<p>2.4.7 Startup After Emergency Shutdown.</p>
<p>2.5 References.</p>
<p>3. Regulatory Issues.</p>
<p>3.1 An Overview of PSSR Industry Guidelines and Regulations.</p>
<p>3.2 Best Practices for PSSR.</p>
<p>3.3 Environmental Considerations.</p>
<p>3.4 General Safety, Security, and Occupational Health Considerations.</p>
<p>3.5 References.</p>
<p>4. A Risk–Based Approach to Pre–Startup Safety Review.</p>
<p>4.1 Using Risk Analysis Techniques to Select the Level of Detail for a PSSR.</p>
<p>4.1.1 A Case of Complexity Versus Simplicity.</p>
<p>4.1.2 The Term Complexity Includes Novelty.</p>
<p>4.1.3 The Effect of Complexity on PSSR Team Size and Expertise.</p>
<p>4.1.4 The Effect on the Level and Scope of the Review.</p>
<p>4.2 A Decision Guideline for Designing a PSSR.</p>
<p>4.2.1 A Definition of Risk–based PSSR. A Qualitative Approach.</p>
<p>4.2.2 An Example Algorithm.</p>
<p>4.3 Typical Considerations for all Pre–startup Safety Reviews.</p>
<p>4.3.1 Hardware and Software: Equipment, Instrumentation, and Process Control.</p>
<p>4.3.2 Documentation: Process Safety Information, Procedures, and Maintenance Management System Data.</p>
<p>4.3.3 Training: Quality and Verification of Completeness.</p>
<p>4.3.4 Special Items: Specific Safety, Health, and Environmental Issues.</p>
<p>4.4 An Example Risk–based Questionnaire.</p>
<p>4.5 Two Examples of Using a Risk–based Approach to PSSR Design.</p>
<p>4.5.1 A Simple PSSR.</p>
<p>4.5.2 A More Complex PSSR.</p>
<p>4.6 References.</p>
<p>5. The Pre–Startup Safety Review Work Process.</p>
<p>5.1 Defining the PSSR System.</p>
<p>5.1.1 Double Checking Management of Change.</p>
<p>5.1.2 Who Is Responsible for Driving the System?</p>
<p>5.2 PSSR Sub–elements.</p>
<p>5.2.1 Construction and equipment meet the designed specifications.</p>
<p>5.2.2 Safety, operating, maintenance and emergency procedures are in place and adequate.</p>
<p>5.2.3 A PHA has been performed for new facilities.</p>
<p>5.2.4 Training of each employee involved in the process is complete.</p>
<p>5.2.5 General requirements.</p>
<p>5.3 Designing and Implementing an Initial PSSR Program.</p>
<p>5.3.1 Defining a Policy on PSSR.</p>
<p>5.3.2 Defining the PSSR Team.</p>
<p>5.3.3 Designing the Specific PSSR.</p>
<p>5.3.4 Training the Workforce on the PSSR Program.</p>
<p>5.3.5 An Example PSSR Program.</p>
<p>5.4 Preparing to Perform a Pre–statup Safety Review.</p>
<p>5.4.1 Gather the Documentation.</p>
<p>5.4.2 Schedule Meetings as Needed.</p>
<p>5.4.3 Verify the Trigger Event Related Work Is Complete.</p>
<p>5.4.4 Identify and Track the Process Hazard Analysis Action Items.</p>
<p>5.5 Follow Pre–startup Safety Review Action Items.</p>
<p>5.5.1 Which Items Are Critical for Safe Operation?</p>
<p>5.5.2 Consider Past PSSR PSM Compliance Audit Findings.</p>
<p>5.6 Approve the Pre–startup Safety Review Report.</p>
<p>5.6.1 Reference the Documentation: Electronic or Hardcopy.</p>
<p>5.6.2 PSSR Team Approval.</p>
<p>5.6.3 Management Approval.</p>
<p>5.7 References.</p>
<p>6. Methodologies for Compiling and Using A PSSR Checklist.</p>
<p>6.1 Building Your Facility s Database of Questions.</p>
<p>6.1.1 Beware of Shortcuts.</p>
<p>6.1.2 Considerations for Different Industries.</p>
<p>6.2 Various Approaches: Electronic versus Hardcopy.</p>
<p>6.2.1 Using your Existing Facility Action Item Tracking System.</p>
<p>6.2.2 Basic Electronic PSSR Checklist Tools.</p>
<p>6.2.3 Electronic Change Management Systems with PSSR Tools.</p>
<p>6.3 An Example Electronic Checklist.</p>
<p>6.3.1 Collapse the Checklist for Simple PSSR.</p>
<p>6.3.2 Expand the Checklist for Complex PSSR.</p>
<p>7. Continuous Improvement.</p>
<p>7.1 Diagnosing PSSR System Issues.</p>
<p>7.2 Training and Communication.</p>
<p>7.3 Examine Excesses as well as Deficiencies.</p>
<p>7.4 Why Refine, Improve, Upgrade, or Redesign?</p>
<p>7.4.1 Workforce Reductions.</p>
<p>7.4.2 Company Restructuring.</p>
<p>7.4.3 Acquisitions, Mergers, and Divestiture.</p>
<p>7.4.4 Regulatory Changes.</p>
<p>7.4.5 Changes in Process Risk.</p>
<p>7.5 Upgrading the System.</p>
<p>7.6 Example PSSR Performance and Efficiency Metrics.</p>
<p>7.6.1 PSSR Performance Indicators.</p>
<p>7.6.2 PSSR Efficiency Indicators.</p>
<p>7.7 Audit Frequency.</p>
<p>7.8 Qualification Considerations for PSSR Auditors.</p>
<p>7.9 Sample PSSR Audit Protocols.</p>
<p>7.10 Addressing Audit Results.</p>
<p>7.11 Summary.</p>
<p>7.12 References.</p>
<p>Appendix A. PSSR Checklist Examples.</p>
<p>Appendix B. Industry References.</p>
<p>Appendix C. Regulatory References.</p>
<p>Index.</p>