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Start-up - Initial

Description

  • Detailed procedural steps must be provided for initial start-up of processes (Scholtz & Maher, 2014).

    • The greatest number of incidents occur during start up (and shut down) procedures, so these procedures must be very clear and accurate (Rowe, 2019).

  • The initial start-up procedure should be used for training and evaluation under Process Hazard Analysis (PHA) and Management of Change (MOC) processes, as well as for the actual operation itself.

  • Initial start-up procedures should include target levels, milestones, consequences, and remedial methods (Cruz-Guerra and Cruz-Gomez, 2002). These components should be updated as necessary when management of change processes occur.

  • Operators are more likely to use procedures for initial start-up than for more frequently performed task procedures, as they have less familiarity with the information (Sasangohar, et al., 2016).

Unique Considerations (Peres et al., 2016)

  • Operators may be unfamiliar with the procedures.
  • Process excursions can occur which require actions to return the operation to a safe operating window.
  • Operators may experience elevated stress due to the uncertainty involved with maiden operations.
  • Possible overlooked or unanticipated hazards may exist.
  • Initial start-up may be performed by or with other stakeholders as well as the operator.
  • Initial start-ups are often conducted at a slower pace with more attention given to individual details than future start-ups.
  • Lessons learned during initial startups should be captured and incorporated into future operating procedures.
Guideline 1: Start-Up Procedure Information Inclusion
Initial start-up procedures should include target levels, milestones, consequences, and remedial methods.

Support
Including information related to the target levels, milestones, consequences of process parameters outside the defined limits, and appropriate remedial methods prevents an operator from having to check other reference materials (Cruz-Guerra & Cruz-Gomez, 2002).
Example
correct
Guideline 2: Image and Diagram Use
Images, diagrams, and other relevant visuals should be used to complement written information when practicable, particularly for infrequently performed procedures.

Support
Pictorial realism (i.e., using pictures and diagrams to illustrate parts) was described by operators as a desirable method to improve procedures’ usability (Sasangohar et al., 2018).
Example
correct