➢ Standard Operating Procedures For Conduct PSSR

Standard Operating Procedure (SOP) for conducting a Pre-Start-Up Safety

Review (PSSR) specifically focused on the process of starting a new tank
after confined space cleaning and maintenance
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SOP Number:

Revision Number:

Effective Date:

Prepared by:

Approved by:

1. Purpose

This Standard Operating Procedure (SOP) outlines the process for conducting a Pre-Start-Up Safety
Review (PSSR) following the cleaning and maintenance of a new tank classified as a confined space. The
PSSR aims to ensure that all safety, health, and environmental systems are functional and that risks are
adequately managed prior to the tank’s introduction into service.

2. Scope

This SOP applies to the start-up of all new tanks that have undergone confined space cleaning and
maintenance and are intended for the storage of hazardous materials, including chemicals, oils, or
solvents.

3. Responsibilities

Process Safety Manager (PSM): Ensures the PSSR is completed in accordance with safety regulations and
that all identified actions are resolved before tank operation.

Project Manager: Coordinates the PSSR process and verifies that all relevant documentation and
inspections are complete and available.

PSSR Team: A multidisciplinary team consisting of operations, engineering, maintenance, and safety
personnel, responsible for reviewing all safety aspects.

Operations Supervisor: Ensures readiness for tank start-up and that all PSSR actions have been
addressed satisfactorily.
 4. Prerequisites

Completion of confined space cleaning and maintenance activities, including atmospheric testing.

Verification of the integrity of the tank and all associated piping systems, including pressure testing as
applicable.

All mechanical, electrical, and instrumentation systems related to the tank must be fully functional and
operational.

A review of the Process Hazard Analysis (PHA) related to the tank, ensuring that all action items identified
in HAZOP studies or risk assessments have been implemented

5. Procedure

5.1 Review Documentation

Prioritise to initiating the PSSR, ensure that the following documentation is reviewed and verified:

Cleaning Verification Report: Documentation confirming that confined space cleaning has been
completed, including atmospheric testing results.

Piping and Instrumentation Diagrams (P&IDs): Updated diagrams that reflect the current configuration
and operational status of the tank.

Operating Procedures: Detailed instructions on the operation of the tank and its associated systems.

Safety Data Sheets (SDS): Relevant information on materials that will be stored in the tank.

Inspection and Testing Reports: Documentation from inspections and tests conducted on the tank and
its associated connections.

Example: A cleaning verification report may indicate that a new tank previously utilized for storing volatile
organic compounds (VOCs) has been thoroughly cleaned, tested for oxygen levels, and confirmed free of
flammable vapors.

5.2 Inspection of Equipment and Systems

Visual Inspection: Conduct a thorough visual inspection of the tank and associated systems to verify
proper installation and integrity.

Functional Testing: Test all safety devices such as pressure relief valves, level alarms, and interlocks to
ensure they are operational.

Control Systems Verification: Validate that all control systems, including automated monitoring systems,
are correctly configured and functioning.

Example : During the visual inspection, check the tank for signs of corrosion, leaks, or improper
connections and ensure that all flanged joints are securely fastened.
 5.3 Verify Safety Measures

Emergency Procedures Review: Confirm that emergency response procedures are in place and
communicated to all personnel involved in tank operations, including protocols for leaks or spills.

Personal Protective Equipment (PPE): Ensure that all personnel involved in the tank start-up have access
to appropriate PPE and are trained in its proper use.

Training Confirmation: Verify that all operators and maintenance personnel have received training on the
specific hazards associated with the tank and its contents.

Permit to Work (PTW) System: Confirm that a PTW is in place for any activities that may pose hazards,
such as hot work or maintenance activities.

Example: Emergency response procedures should include specific actions to be taken in case of a spill
or leak, as well as evacuation routes and contact numbers for emergency response teams.

5.4 HAZOP and Risk Assessment Review

Review the findings from any HAZOP studies or other risk assessments related to the tank. Ensure that all
identified safety controls and recommendations have been implemented.

Example: If the HAZOP identified the need for additional secondary containment for potential leaks,
ensure that such containment measures are in place and functional.

5.5 Operational Readiness

Ensure that all operational procedures relevant to the tank are updated and that operators are familiar
with them. Confirm that commissioning checklists for the tank and associated systems have been
completed.

Example: A commissioning checklist may include items such as ensuring that all valves are correctly
positioned, that the tank is properly labeled, and that pressure and temperature monitoring systems are
functional.

5.6 Final Walkthrough

Conduct a final walkthrough of the tank area to verify the following:

All safety systems are operational and correctly configured.

Hazardous materials have not been introduced into the tank until it is ready to be filled.

Access routes, emergency exits, and safety signage are clearly marked and unobstructed.

Example: During the final walkthrough, ensure that the emergency shut-off controls are easily accessible
and that all safety signage is visible to personnel in the vicinity.
5.7 Review and Sign-off

Final PSSR Checklist: Ensure that each section of the PSSR checklist is completed. Each item should be
marked as complete, pending, or requiring further action.

Signatures: The PSSR should be signed off by responsible personnel, including the Process Safety
Manager, Project Manager, and Operations Supervisor, confirming that all actions have been adequately
addressed.

6. Reporting and Documentation

PSSR Report: A formal report summarizing the findings of the PSSR, including any outstanding issues and
necessary sign-offs, should be prepared.

Document Retention: All documentation related to the PSSR must be stored in accordance with
company policy and applicable regulatory requirements.

7. Actions After PSSR

Start-Up Authorization: No startup of the tank should occur until all findings from the PSSR have been
resolved or approved to proceed with appropriate risk mitigation measures.

Review of Changes: If any modifications or changes occur during or after the PSSR, these should be
evaluated to determine whether a new PSSR or a partial review is necessary.

8. Revision Control

This SOP should be reviewed annually or whenever significant changes occur in the PSSR process.

9. Key Elements of Safety Influence

STOP Principles: Emphasize behavioural safety by involving all personnel in hazard identification and
mitigation strategies.

Process Safety Management (PSM): Align with OSHA’s PSM guidelines, focusing on management of
change, PHA, and mechanical integrity.

Risk-Based Approach: Implement risk assessments for all aspects of the tank start-up process to
mitigate overlooked hazard
Documents Required for PSSR

1. Cleaning Verification Documentation

Confined Space Entry Permit: Evidence that all safety protocols were followed during the cleaning
process, including atmospheric testing results (oxygen levels, flammable gases, and toxic substances).

Cleaning Report: Summary of the cleaning activities conducted, including any observations, issues
encountered, and corrective actions taken.

2. Process Safety Documentation

Process Hazard Analysis (PHA) Reports: Completed PHA, including any HAZOP studies, risk
assessments, or layer of protection analysis (LOPA) that outline potential hazards and risk mitigation
measures.

Management of Change (MOC) Documentation: Records of any changes made to the process,
equipment, or procedures that triggered the PSSR, including risk assessments related to those changes.

3. Technical Documentation

Piping and Instrumentation Diagrams (P&IDs): Updated diagrams that accurately reflect the tank’s
configuration and associated systems, showing all connections, control points, and safety devices.

Process Flow Diagrams (PFDs): Diagrams that depict the flow of materials through the tank and
associated systems, providing clarity on operational sequences.

Equipment Specifications and Manuals: Detailed specifications, operating instructions, and

maintenance manuals for the tank and its associated equipment.

4. Safety Documentation

Safety Data Sheets (SDS): SDS for all materials that will be stored in the tank, providing critical
information on hazards, handling procedures, and emergency measures.

Emergency Response Procedures: Established procedures for responding to emergencies specific to the
tank’s operation, including spill response, fire, or exposure incidents.

5. Inspection and Testing Reports

Inspection Checklists: Completed checklists verifying that all components of the tank and associated
systems have been inspected.

Testing Results: Reports on functional tests conducted on safety devices (e.g., pressure relief valves,
alarms) to confirm operational integrity.
 6. Operational Procedures

Standard Operating Procedures (SOPs): Up-to-date operating procedures for tank operations, detailing
step-by-step instructions for filling, monitoring, and maintaining the tank.

Startup and Shutdown Procedures: Specific procedures outlining the safe start-up and shutdown
processes for the tank.

7. Training Documentation

Training Records: Evidence that all personnel involved in the operation of the tank have received
appropriate training regarding hazards, PPE, emergency procedures, and operational protocols.

Competency Assessments: Records of assessments conducted to verify that personnel are competent in
their roles related to the tank’s operation.

8. Permit to Work (PTW) Documentation

PTW Records: Completed permits for any high-risk activities, such as hot work or maintenance work, that
may affect the tank operation or safety.

9. Risk Assessment Documentation

Risk Assessment Reports: Documentation detailing any risk assessments conducted regarding the tank,
including identified hazards and proposed control measures.

10. Final PSSR Checklist

PSSR Checklist: A comprehensive checklist that includes all required elements to be reviewed during the
PSSR, ensuring all safety aspects have been addressed before start-up.

Example of Document Preparation

Before conducting the PSSR for a newly cleaned and maintained tank, ensure that all the documents
listed above are compiled, verified, and readily available. For instance, if the confined space cleaning
report indicates that all flammable vapors were effectively removed, this should be documented with
atmospheric testing results attached.

Additionally, all personnel should have received training specific to the tank’s hazards and operational
procedures, and their training records should be accessible for review during the PSSR.

By ensuring all documentation is in order, the PSSR process can be conducted efficiently, effectively
mitigating potential risks associated with the tank’s operation.

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