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01/06/2022

CORPORATE PROCEDURE FOR PLANT PRE-START-UP

SAFETY REVIEW (PSSR)
DOC NO: CORP -ENG-PRC-009
(Formerly: IP-ENG-039)
Rev: 01
Quality Reviewed By: Formatted
Only

CUSTODIAN DEPARTMENT DOCUMENT AUTHOR DOCUMENT OWNER

Digitally signed by Digitally signed by

Haytham Haytham
Abduljawad
Fahad Al-Ansari
PROJECT SERVICES (PS) Abduljawad Date: 2022.04.20 Date: 2022.05.12
11:17:03 +03'00' 14:44:06 +03'00'
PSS PS

EVP

2022.05.15
08:03:09
+03'00'
VP

FINAL APPROVAL

Digitally signed by Saad Sherida

Alkaabi
Date: 2022.05.22 09:51:12
+03'00'
PRESIDENT AND CEO
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DOC NO: CORP-ENG-PRC-009 REV. 01

TABLE OF CONTENTS

Page No.

PURPOSE ............................................................................................. 3
SCOPE AND APPLICABILITY.............................................................. 3
ROLES AND RESPONSIBILITIES ....................................................... 3
PROCEDURAL STEPS ......................................................................... 4
4.1 OVERVIEW ............................................................................................................ 4
4.2 IDENTIFY PLANT PRE-START-UP SAFETY REVIEW REQUIREMENTS ........... 5
4.3 PREPARE PROJECT SPECIFIC PLANT PRE-START-UP SAFETY REVIEW
PROCEDURE .................................................................................................................. 5
4.4 PERFORM PLANT PRE-START-UP SAFETY REVIEW........................................ 5
4.5 INFRASTRUCTURE AND CIVIL PROJECTS ........................................................ 6
REFERENCES TO OTHER DOCUMENTS ........................................... 7
DEFINITIONS ........................................................................................ 8
APPENDIX................................................................................................... 10
APPENDIX A - REVISION HISTORY LOG .................................................................... 10
APPENDIX B - LIST OF ABBREVIATIONS ................................................................... 11
APPENDIX C - FLOWCHART - PLANT PRE-START-UP SAFETY REVIEW (PSSR) .. 12
APPENDIX D - PLANT PRE-START-UP SAFETY REVIEW CHECKLIST .................... 13

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PURPOSE
This corporate Procedure is a supplement to Commissioning and Handover Procedure
CORP-ENG-PRC-005 and defines the process, interfaces, key deliverables and required
approvals for the planning, preparation, and execution of a Plant Pre-Start-up Safety Review
for projects executed by the VP Directorate.

SCOPE AND APPLICABILITY

This Procedure applies to all capital projects executed by VP Directorate within
QatarEnergy. It applies to onshore and offshore oil & gas production, processing and
transmission facilities, refinery, infrastructure and civil projects, and associated utilities and
auxiliaries.

ROLES AND RESPONSIBILITIES

PROJECT TEAM

• Assists with Identification of the Plant Pre-Start-up Safety Review

requirements.
• Assists with the development of the project-specific Plant Pre-Start-up Safety
Review Procedure, including the checklists.
• Assists the Commissioning Team with performing the Plant Pre-Start-up
Safety Review.
• Assists with the Plant Pre-Start-up Safety Review Closeout Report.
• Manages resolution of any issues discovered during the safety review with
support from the Commissioning Team, Contractor, and vendors as needed.

COMMISSIONING TEAM

• Assists the Project Team with resolution of issues identified during the Plant
Pre-Start-up Safety Review.
• Ensures that Pre-Commissioning and Commissioning activities of all
Equipment and Systems are completed.
• Leads the identification of the Plant Pre-Start-up Safety Review requirements.
• Leads the development of the project-specific Plant Pre-Start-up Safety
Review Procedure including the checklists.
• Leads the Plant Pre-Start-up Safety Review.
• Leads development of the Plant Pre-Start-up Safety Review Closeout Report
Signs-off the Plant Pre-Start-up Safety Review Checklist.

ASSET HOLDER, OPERATIONAL HSE

• Assists with Identification of the Plant Pre-Start-up Safety Review

requirements.
• Assists with the development of the project-specific Plant Pre-Start-up Safety
Review Procedure, including the checklists.
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• Assists with resolution of outstanding issues identified during the Plant Pre-
Start-up Safety Review as needed.
• Assists with the Plant Pre-Start-up Safety Review Closeout Report.
• Participates in the Plant Pre-Start-up Safety Review.
• Reviews the completed checklists indicating that Pre-Commissioning and
Commissioning activities of all Equipment and Systems are completed.

PROCEDURAL STEPS
A flowchart of the Plant Pre-Start-up Safety Review process is included as Appendix C.
4.1 OVERVIEW
The most critical phase of any project is the Start-Up phase when process fluid is introduced
in the Plant or the facility is energized, depending on the project scope. Incidents may occur
during this phase due to any one-off, or combination of, the following:

• Safety Systems not in place or not function properly.

• Process and utility systems not lined up properly.
• Urgency to Start-Up the Plant or facility.
• Operational constraints.
• Inadequate training given to operations and maintenance staff.
• Non-availability of Start-up and operating Procedures.

To prevent these incidents, a Plant Pre-Start-up Safety Review shall be performed before
introduction of process fluid into the Plant or energizing systems for facilities without process
fluids. However, this Procedure is not intended to replace the meticulous activities that
should be performed by the Commissioning Team prior to Start-Up, which are covered in
project-specific Start-Up Procedures as referenced in CORP-ENG-PRC-005 (Project
Commissioning and Handover).
The objectives of a Plant Pre-Start-up Safety Review (PSSR) are:

• To ensure that all necessary documents are in place to demonstrate that

Equipment, Systems and Plant pre-commissioning and commissioning have
been completed in accordance with project specific requirements.
• To ensure that the relevant operating and maintenance manuals and
Procedures are in place, initial spares available, and that the safety-critical
equipment and Criticality "1" equipment's data has been entered into SAP.
• To ensure that adequate operator and maintenance personnel training has
been performed.
• To assess and eliminate any potential hazards that may be experienced during
the Start-Up and operation of a Plant or facility.

The above objectives are achieved by:

• Visual checks and physical inspection of the facility.

• Ensuring the availability of operating and maintenance Procedures.

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• Ensuring that all safety systems are in place, certified and operational
(including emergency response). Note that safety function checks shall be
carried out for the Equipment and Systems prior to Commissioning as per the
project-specific Procedures.
• Ensuring that process and utility systems are ready for line-up for introduction
of hydrocarbon or process fluid or are ready to be energized.
• Ensuring that all ESD and Control Systems are operational.

4.2 IDENTIFY PLANT PRE-START-UP SAFETY REVIEW REQUIREMENTS

The Commissioning Team that is led by an Asset Holder representative shall lead
identification of the Plant Pre-Start-up Safety Review requirements with support from the
Project Team during preparation of the Commissioning Plan as per Procedure CORP-ENG-
PRC-005.
In the case where the project scope includes only minor modifications or upgrades of the
existing facilities that does not change the basic operation of the plant, the Plant Pre-Start-
up Safety Review will be limited to the modified facilities only.
4.3 PREPARE PROJECT SPECIFIC PLANT PRE-START-UP SAFETY REVIEW
PROCEDURE

a. The Commissioning Team shall lead the development of a project-specific

Plant Pre-Start-up Safety Review Procedure with support of the Asset Holder,
Project Team, Contractor, and vendors as needed. The criteria for PSSR shall
be as defined and agreed in the project-specific Commissioning Plan (refer
CORP-ENG-PRC-005).

This Procedure should include as a minimum:

• Methodology.
• Plant Pre-Start-up Review Checklist (a sample checklist is attached as
Appendix D for reference).
• Reference documents.
• Roles and Responsibilities of the parties involved.

b. The Commissioning Team, Project Team, Asset Holder, and Operational

HSE representatives shall review this Procedure for completeness.

4.4 PERFORM PLANT PRE-START-UP SAFETY REVIEW

The Commissioning Team shall perform the Plant Pre-Start-up Safety Review with support
from the Project Team, Operational HSE and Asset Holder.

a. The Commissioning Team and Project Team shall ensure that Pre-
Commissioning and Commissioning activities of all Equipment and
Systems are completed before initiation of the Plant Pre-Start-up Safety
Review.
b. The Commissioning Team, Project Team and Operational HSE will perform
the Plant Pre-Start-up Safety Review as per the approved project-specific

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Plant Pre-Start-up Safety Review Procedure. The safety review shall be

performed after completion of Commissioning of Equipment and Systems
but before introduction of process fluid into the Plant or energizing facilities.
c. The Plant or facility shall be thoroughly checked as per the Plant Pre-Start-
up Safety Review Checklists (refer to Appendix D). The Project Team, with
assistance from the Commissioning Team, Contractor and vendors shall
closeout any outstanding issues identified during the safety review that can
potentially compromise the safety of the Plant or facility.
d. The Commissioning Team shall ensure that all outstanding issues identified
during the safety review have been resolved with support by the Project
Team, Contractor, and vendors. After all items listed in the Plant Pre-Start-
up Safety Review Checklists are completed, the Commissioning
Coordinator (Project Team), Commissioning Coordinator (Asset Holder)
and Commissioning Team Leader from Asset Holder shall sign the
checklists.
e. Upon successful completion of the Plant Pre-Start-up Safety Review, the
Commissioning Team shall prepare the Plant Pre-Start-up Safety Review
Close-out Report, including signed-off checklists with the support of the
Project Team. The report shall be approved by the Commissioning Team
and forwarded to the Asset Holder with the Ready for Start-up Certificate
(as per CORP-ENG-PRC-005).

4.5 INFRASTRUCTURE AND CIVIL PROJECTS

Depending on the scope of commissioning activities, Infrastructure and Civil Projects may
have reduced requirements for preparation and testing. Details on the preparation and
testing requirements are developed in the project-specific Commissioning Plan. Refer to
Section 4.8 of CORP-ENG-PRC-005 – Commissioning & Handover for related guidelines

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REFERENCES TO OTHER DOCUMENTS

TABLE 1: REFERENCES TO OTHER DOCUMENTS

Internal/External
Document Document
Document Title Document (if
Number Referencing
any)

Corporate Procedure for

CORP-ENG-PRC-
Project Stage Gate Approval Internal Sideways
001
Process

Corporate Procedure for

CORP-ENG-PRC-
Project Commissioning and Internal Sideways
005
Handover

Note 1: Corresponding new QatarEnergy management system document numbering

terminology for old QP level documents are provided above as reference.
Note 2: The old QP document numbers referred herein this document will be updated as
per the Quality Management Refresh project requirements and with new QatarEnergy
logo and new document number at an appropriate time.

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DEFINITIONS
TABLE 2: KEY TERMS DEFINED

Term Definition

Asset Holder Directorate / Department operating the facilities. In case of

Development/Redevelopment projects also VU is asset holder for
the reservoir.

Commissioning Phase of the project after Pre-Commissioning to dynamically

verify the functioning and operation of the Equipment or
System(s) in accordance with specified requirements, to achieve
stabilized operation of relevant Equipment or System(s) and
carry out Site Acceptance Tests, as applicable. For the Plant, the
commissioning activity is to complete remaining activities before
Start-Up.

Commissioning Team established to facilitate the Commissioning and Handover

Team process as described in Section 4.2.1 of CORP-ENG-PRC-005.

Equipment Item that may be part of a System and be commissioned

independently, however, it may or may not be operated
independently.

Handover Transfer of responsibility for Equipment, Systems or Plant from

the Project Team to the Asset Holder.

Mechanical The completion and documentation of inspection and testing of

Completion workmanship and materials, to prove and validate the complete
and correct execution of construction or modification, in
accordance with the AFC documents.

Plant Overall facilities constructed or revamped under a project

comprising of various Equipment and/or Systems.

Policy Intentions and direction of an organisation as formally expressed

by its top management.

Pre-Commissioning The phase of the project before Mechanical Completion and prior
to Commissioning in which the operational status and functioning
of the Equipment, System(s) or Plant is validated as acceptable.
This includes initial inspections, tests, checks, etc.

Procedure Specified way to carry out an activity or process.

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Project Manager QatarEnergy person from VP Directorate who has overall

responsibility for the execution of projects assigned to the
Division.

Project Team Team members in the VP Directorate responsible for the

management and execution of the project.

Shall Mandatory action or requirement.

Should Preferred course of action.

Start-Up Stage at which process fluid is introduced into the Plant. It is

defined as operation of all the facilities under the project. It can
only be performed once Commissioning of all associated utilities
and auxiliaries and Pre-Commissioning activities of the Plant
have been completed and accepted by the Asset Holder.

System Stand-alone facility/utility, associated with a Plant, which can be

commissioned and may be operated independently.

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APPENDIX

APPENDIX A - REVISION HISTORY LOG

TABLE 3: REVISION HISTORY LOG

Revision Number: 01 Date22/03/2022

Item Revised Revision Description Page No.

IP-ENG-039 Rev Issued for Use. All

A1. Nov 2009

IP-ENG-039 Rev Fast-Track update to only reflect the new organizational All
A1.2. Sept 2015 changes.

CORP-ENG- A new corporate level document was introduced as a part All

PRC-009 Rev.00 of “Tatweer- QatarEnergy Project Management
May’ 2018 Transformation Project” to describe the process for Plant
Pre-Start-up Safety Review.

CORP-ENG- Document converted to QatarEnergy document template All

PRC-009 Rev.01 as per EPPF Quality Management Refresh project
March 2022 transition plan for “simplification” of QMS documents

Remarks:

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APPENDIX B - LIST OF ABBREVIATIONS

TABLE 4: LIST OF ABBREVIATIONS

Abbreviation Description

EPIC Engineering, Procurement, Installation and Commissioning

ESD Emergency Shutdown

FEED Front End Engineering Design

PSSR Plant Pre-Start-up Review

SOW Scope of Work

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APPENDIX C - FLOWCHART - PLANT PRE-START-UP SAFETY REVIEW (PSSR)

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APPENDIX D - PLANT PRE-START-UP SAFETY REVIEW CHECKLIST

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