Document Title

The Tata Power Company Ltd PSSR Procedure

Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03

Pre Start-up Safety Review (PSSR) Procedure

Rev
Reason for Revision Prepared By Checked By Approval by
No.
R00 Initial Issue R&P Sub Committee D Kamath Vijay Chourey

R01 Standardization of procedure

Navendra Singh
Vijay Chourey
Bhavin Bhansali (Chief – Corp Safety)
(Group Head – P &
(Asso. Group Head – CB; Corp Safety.)
EMD, CGPL.)
Navendra Singh Rajesh Sharma Suresh Khetwani
Head- Safety (T&D) Head- Safety Chief - Corporate Safety &
R02 Periodic revision
Corp safety (Generation) Corp Environment
safety
Navendra Singh Rajesh Sharma Suresh Khetwani
Head- Safety (T&D) Head- Safety Chief - Corporate Safety &
R03 Periodic revision
Corp safety (Generation) Corp Environment
safety

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03

Contents

Section Description Page No.

1.0 OBJECTIVE 3
2.0 SCOPE 3
3.0 EXPECTED RESULTS 3
4.0 ACCOUNTABILITY & RESPONSIBILTIY 3
5.0 GLOSSARY/ DEFINITIONS 3
6.0 PROCEDURES 3
7.0 RECORDS 5
8.0 TRAINING & COMMUNICATION 5
9.0 VERIFICATION 5
10.0 EXCEPTIONS 5
11.0 REFERENCES 5
12.0 REVIEW 6
13.0 ATTACHMENTS/APPENDIX 6
- Pre Startup Safety Review (PSSR) Checklist - 7
TPSMS/GSP/PSSR/010/FORM/001

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03

1. OBJECTIVE:

Objective of this procedure is to provide guidelines for safe initial startup of a new facility
or restart of a modified facility. The PSSR process verifies that the new/modified facility
meets the original design and operating parameters. The intent is to prevent incidents
caused by inadequate, incomplete, unauthorized design, construction, installation,
and/or commissioning. .

2. SCOPE:
This procedure applies to all operating plants and project sites of Tata Power Group
companies including JVs/Subsidiaries.

3. EXPECTED RESULTS:
3.1. All New facility and modified facility meets the original design and operating intent of
process plant/facility.
3.2. Safety, operating, maintenance and emergency procedures are in place and adequate
3.3. Any site modifications during construction phase have been properly controlled and
noted.

4. ACCOUNTABILITY & RESPONSIBILITY:

4.1. ACCOUNTABILITY: Concerned Division’s Heads/Assets Custodian.
4.2. RESPONSIBILITY: As defined in the procedure.

5. GLOSSARY/ DEFINITIONS:
MOC: Management of change
PPE: Personnel Protective equipment
PSSR: Pre Startup Safety Review
Procedure: Specified way in carrying out an activity or process
Shall: Mandatory requirement
Should: Optional requirement
Statutory requirements: Laws, regulations applicable at the location of plant /work.

6. PROCEDURES:

6.1. Following activities shall be carried out in a PSSR with coordination between
Construction personnel and Owner (Operations) & Maintenance Personnel and Safety
personnel of the plant / facilities:

a. Coordinate PSSR participation from knowledgeable Construction ( Electrical,

Mechanical, Civil and Instrumentation) personnel and Owner ( Operation ) &
Maintenance Personnel ( Mechanical , Electrical , Instrumentation , Civil ) and Safety
personnel.
b. Conduct Technical and HSE reviews of documentation and on site

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03
c. Verify all construction and equipment is in accordance with safety, environmental
and health rules & regulation and standards.
d. Complete all corrective action items raised in the PSSR
e. Complete Post- Start-up corrective action items
f. Representative of the Project Owner sign the PSSR checklists for approval of
commissioning/start-up of the plant.
g. Documentation of PSSR.

6.2. Pre Startup Safety Review (PSUSR) Practices: PSSR shall be conducted by a team,
lead by a Leader. The leader is normally a representative of operation group because
they are the ultimate customer of the facility. A PSSR process shall consists of 3 steps:

6.2.1. Follow-up HAZOP Review: includes the following activities:

6.2.1.1. Verification on the follow-up action items provided by project on

recommendations from previous HAZOP study.

6.2.1.2. Systematic review of all changes to the design since the previous HAZOP
study.

6.2.1.3. The support documents for follow-up HAZOP review should be:

a. Engineering Flow Schemes or P& IDs

b. Utility Flow Schemes or P&IDs
c. Lists of site modifications since the original HAZOP study
d. Process Safeguarding Philosophy.
e. Operating and control philosophy, Cause and effect diagram
f. Other support documentation.

6.2.2. Documentation Review: The documentation review is to check the availability

and status of operating manuals, startup/shutdown and emergency procedures.
Following documents shall be checked for availability and status:

a. Operating manuals/procedures
b. Emergency procedures
c. Instruction of handling of chemicals
d. Operation checklists on safety equipment
e. Safeguarding Philosophy
f. As-built P&IDs/PFDs ( Process Flow Diagram)
g. Area Classification drawings, Plot Plans etc.
h. Fire Protection drawings

6.2.3. Technical HSE Site Review: Technical HSE Site Review shall be carried out
when the construction is nearing mechanical completion (about 90-95 %
completion) and the site is reasonably accessible. The site review shall concentrate
on such issues but nor limited to as:

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03
i. Equipment operability and maintainability
ii. Outstanding punch list items from mechanical completion associated with
PSUSR
iii. Access and exit routes for operators and maintenance personnel
iv. Small-bore connections
v. Location of emergency and safety equipment, warning signs
vi. Safe location of vent lines
vii. Locking systems
6.3. A multidisciplinary team of PSSR trained people from different department (e.g. Const-
Mech, Const-Elect, Commissioning, Operation, & Safety) shall carry out inspection of
the ready to start facilities prior to taking into operation.

6.4. PSSR shall be carried out to understand various safety issues prior to operation and
observations shall be categorized into three categories “A” ,”B” & “C”. Criteria for
ascertaining category of observation is given below-

6.4.1. Category “A” – Observations of non-conformance of any Risk involved related to

safety requirements.

6.4.2. Category “B” – Observations of Non-conformance of any Risk involved related to

process/operation.

6.4.3. Category “C” - All Observations other than not covered in category “A” and “B”.

6.5. No facility can be taken into operation if category “A” points are not resolved. Category
“B” can be resolved within a week’s time and Category “C” can be resolved within a
fortnight’s time.

7. Records:

7.1. Pre Startup Safety Review (PSSR) Checklist – Life time of the facility

8. Training & Communication:

8.1. Training of Safety Communication shall be included and covered in Safety Training
Calendar as per Safety Training needs.

8.2. Initial Communication to be done through Corporate Communication, Email and

subsequently shall be made available at safety portal at Sangam.

9. VERIFICATION

9.1. Verification of implementation shall be done during Safety audit, field safety visit and
site inspections.

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03

10. Exceptions: Any Exception to this procedure shall only be done as per Document Control
Procedure (TPSMS/GSP/DC/014).
11. REFERENCES
• Indian Factory Act 1948 and State Factory Rules
• Electricity Act and Rules

12. Review:
12.1. Review of this procedure shall be done as and when but not later than once in every
three (03) years. Typical Factors like Changes in legislation, Review of Incident
Reports, Inspection & Audit findings, Feedback from users, Recommendations in
Incident investigation reports may be inputs for the review and revision of the
procedure.
12.2. In case release of revised procedure gets delay due to obtaining feedback or any other
reasons, safety advisory may be issued immediately to take precautions for the
proposed changes in the procedure and revised procedure should be released
subsequently.

13. ATTACHMENTS/APPENDIX :
Annexure 1- Pre Startup Safety Review (PSSR) Checklist -TPSMS/GSP/PSSR/010/FORM/001

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03

Annexure – 1
TPSMS/GSP/PSSR/010/FORM/001

Pre Startup Safety Review (PSSR) Checklist

Division: Name of Unit for PSSR:

PSSR REPORT (Pre start-up Safety Review)

PSSR Document Category

No
Package / System
A Hold up
/ Facility
Date Within One
B
week
Time C One month

Persons Present:

Sr. Observation Corrective Responsibility Target Status

Concern Category
No. / status Action (Department) Date
Structural /
mechanical /
1
electrical
completion
Entry and exit
2 including
emergency exit.
Ventilation /
Illumination / dust
ingress protection /
3 Emergency/ bake
up for Illumination
& Auxiliary

4 Fire detection

Fire protection /
5 Drainage system
6 Pest & Reptile
control

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03
7 Labeling & signage

Sr. Observation Corrective Responsibility Target Status

Concern Category
No. / status Action (Department) Date
Equipment Integrity
aspect – Inspection
8 / Test / Calibration
certification

Design intension &

Equipment trip
alarm design basic
9
/ Logic diagram
review

Safety systems –
verification & test
10
report for suitability

Verification of
electrical
equipment for
11 hazardous area
classification &
ingress protection

HAZCHEM- as per
12 MSDS review

Review of Services
air / Service water /
Controlled Air /
13
Drinking water /
Horticulture water

Color code of
process pipe lines
15
& Equipments

Buried cables
16 / Service lines
-route marking

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03
Availability of as
17 built drawings

Sr. Observation Corrective Responsibility Target Status

Concern Category
No. / status Action (Department) Date

Availability of
operation
procedures for
commissioning
18 startup
&Emergency shut
down and Training
of
Operational staff
Maintenance
procedure for
isolation, draining,
depressurization,
19 decontamination,
de-energization,
Locking
& tagging
Ergonomics&
20 Occupational
health
HAZOP Study or
21 HIRA as applicable

Statutory
requirements (Pr.
Vessel, Relief
22 valves, Lifting
equipment,
electrical)
General safety
(PPE,
Safety shower,
23 Emergency contact
nos. Visual display
etc
Emergency
24
preparedness and

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 Document Title
The Tata Power Company Ltd PSSR Procedure
Document No.
Date of Issue: 01/04/2022
TPSMS/CSP/PSSR/014 REV 03
response

25 Housekeeping
Sr. Observation Corrective Responsibility Target Status
Concern Category
No. / status Action (Department) Date

26 Any Other
Name &
Signatures of
Team Members
Team Lead

Member -1
Member -2

Member -3

Member -4

Member -5

Note:

Category “A” – Observations of non-conformance of any Risk involved related to safety

requirements.

Category “B” – Observations of Non-conformance of Risk involved related to

process/operation.

Category “C” - All Other Observations other than not covered in category “A” and “B”.

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