Pre-Startup Safety Review (PSSR), Pre-commissioning and Commissioning of an EPF

Introduction

The successful startup and operation of an Early Production Facility (EPF) in the oil and gas industry is a critical milestone in any upstream development project. This process begins long before the first barrel of oil is produced—starting with Pre-Startup Safety Review (PSSR), Pre-commissioning, and culminating in Commissioning. These structured activities ensure that all systems are safe, functional, compliant, and aligned with design intent. Their execution is not merely procedural; they embody a safety philosophy and operational readiness framework that protects people, the environment, and investments.

An EPF, designed to process hydrocarbons at the early stages of production, consists of a range of mechanical, electrical, instrumentation, and control systems. Before these systems are brought online, a rigorous sequence of checks, validations, and simulations is required. This article delves into the phases, steps, procedures, key considerations, and scheduling strategies that make PSSR, Pre-commissioning, and Commissioning successful. Through real-life insights, structured frameworks, and worksheets, we aim to empower engineers, operators, and project stakeholders with the clarity and confidence to execute safe and efficient facility startup.

Core Section 1: Phases of PSSR, Pre-commissioning, and Commissioning

1.1 Engineering Completion Phase

One-liner: "Ensures all equipment and systems are built and documented as per design."

Practical Insight: "Completion dossiers including as-built drawings, test certificates, and vendor documents are compiled and verified."

Tip: Maintain a centralized digital database for completion documents.

1.2 Pre-commissioning Phase

One-liner: "Validates the integrity and readiness of individual systems before introducing fluids."

Practical Insight: "Pressure testing of pipelines revealed a flange leak, allowing repair before commissioning."

Tip: Follow system-specific checklists for mechanical, electrical, and instrumentation systems.

1.3 PSSR Phase

One-liner: "A final safety and operational check prior to energization or introducing hydrocarbons."

Practical Insight: "A blocked vent line was discovered during a PSSR walkthrough, preventing potential overpressure."

Tip: Involve multidisciplinary teams in the PSSR walkthrough.

1.4 Commissioning Phase

One-liner: "Systems are energized, tested under load, and integrated for production."

Practical Insight: "Simulated startup sequences prevented instrument overloads."

Tip: Conduct dry runs before wet commissioning.

1.5 Start-up and Handover

One-liner: "Transition from project to operations with final validation and performance assurance."

Practical Insight: "An integrated team ensured that the transition was seamless, with minimal production delay."

Tip: Include operational personnel early in the commissioning process.

Core Section 2: Steps and Procedures

2.1 Pre-commissioning Steps

• Mechanical Completion verification (MC Dossiers)

• Flushing and cleaning of piping systems

• Hydrotesting and leak tests

• Instrument loop checks

• Cold electrical checks (megger tests, continuity)

• Safety system validation (fire and gas, emergency shutdown)

2.2 PSSR Procedures

• Review of work permits and punch list closures

• Review of operational manuals and emergency procedures

• Site walkthrough with operations, HSE, and maintenance teams

• Validation of signage, access ways, and safety barriers

• Confirmation of system isolation and lockout-tagout (LOTO) adherence

2.3 Commissioning Procedures

• Energization of systems (electrical and control)

• Calibration of control systems and final loop checks

• Functional testing of equipment under simulated or actual conditions

• Introduction of hydrocarbons or process fluids (wet commissioning)

• System ramp-up and monitoring

• Trip testing and safety override functionality

Core Section 3: Key Considerations for Safe and Efficient Execution

3.1 System Readiness

One-liner: "A system is only ready when all its components pass their individual and integrated tests."

Practical Insight: "Overlooking an earthing check on a transformer delayed energization by 48 hours."

Tip: Implement a readiness checklist for each system.

3.2 Documentation and Control

One-liner: "Complete and correct documentation ensures traceability and regulatory compliance."

Practical Insight: "A missing vendor calibration certificate raised red flags during final inspection."

Tip: Assign a documentation controller to track PSSR sign-offs.

3.3 Health, Safety, and Environment (HSE)

One-liner: "Safety systems must be operational before any energization or fluid introduction."

Practical Insight: "A firewater system test revealed a valve alignment error, rectified before startup."

Tip: Conduct pre-startup HSE audits and toolbox talks.

3.4 Roles and Responsibilities

One-liner: "Clear accountability accelerates execution and issue resolution."

Practical Insight: "Assigning system owners minimized handover delays."

Tip: Maintain a responsibility assignment matrix (RAM).

3.5 Change Management

One-liner: "Even minor changes can have significant implications during startup."

Practical Insight: "A control logic modification not communicated to operations caused a shutdown."

Tip: Implement a Management of Change (MOC) procedure for all scope changes.

Core Section 4: Scheduling and Coordination

4.1 Integrated Commissioning Schedule

• Include interdependencies between systems

• Factor in vendor availability and mobilization timelines

• Allow time for rework and punch list clearance

4.2 Simultaneous Operations (SIMOPS)

• Identify and mitigate SIMOPS risks (e.g., hot work during testing)

• Coordinate with construction and operations teams

• Develop a SIMOPS management plan

4.3 Float and Contingency Planning

• Allocate float for high-risk activities

• Maintain a commissioning risk register

• Schedule contingency meetings to assess progress and resolve issues

4.4 Handover Timeline

• Define acceptance criteria for handover

• Establish joint inspection and sign-off protocols

• Prepare final performance testing and operational readiness reports

Core Section 5: Practical Worksheets and Templates

Worksheet 1: PSSR Readiness Checklist

Worksheet 2: Commissioning Sequence Plan

Worksheet 3: Punch List Tracker

Worksheet 4: SIMOPS Risk Matrix

Conclusion

PSSR, Pre-commissioning, and Commissioning of an EPF are not just technical milestones; they are the embodiment of safety, quality, and operational excellence. These processes ensure that every component of a complex facility is validated, every risk is mitigated, and every system is ready to perform safely and reliably. The disciplined execution of these activities protects lives, preserves assets, and supports sustainable production.

By understanding the phases, applying structured steps, considering safety and operational nuances, and leveraging detailed schedules and worksheets, project teams can avoid costly delays, incidents, and reputational damage. Successful facility startup is a result of rigorous preparation, teamwork, and commitment to excellence. It marks not the end of a project, but the beginning of a safe and productive operational life. Embrace the process, empower your teams, and ensure your EPF starts strong and safe.