Post-startup review

The first process review should be conducted shortly after startup to verify that the tolling operations are within the scope of the final technology package. The post-startup process review can be 

This post-startup review team should report the results of their review to the management of the business unit responsible for the final tolled product. If operating parameters or equipment configurations different from those approved in the technology package, management should promptly assess any risk associated from the variances and either  

A toller may be operating the first scale-up of a process that has previously only been produced in pilot quantities. This pre-startup situation benefits when special concerns related to a scale-up are monitored. 

Simple mixing of raw materials and intermediates may present special problems when processing significantly larger quantities in comparison to the pilot process or laboratory bench amounts. All aspects of the toll should be considered while performing the PHA to identify potential problems caused by the scale-up. 

The following sections provide guidance and some examples for addressing these ongoing activities. The flowchart on the next page shows a typical sequence of ongoing operations and audits. 

---

What makes an effective post-startup review ... 

Initial startup testing procedures have been prepared and implemented to demonstrate that structures, systems, and components (SSCs) and processes will perform as intended. Initial testing includes, as appropriate, bench tests and proof tests prior to installation, mockup tests, pre-operational tests, post-maintenance tests, post-modification tests, and operational startup tests. Safety-related items are subject to the quality-assurance requirements of SNL/NM Research Reactor and Experimental Programs (RREP) Quality Assurance Program Plan (SNL 1998a), as implemented by the facility Project/Experiment Quality Plan (PEQP). Testing inciudes those initial tests mandated by applicable Technical Safety Requirement (TSR) surveiilance requirements (see Chapter 5.0, "Derivation of Technical Safety Requirements") and Operational Readiness Review (ORR) requirements (see DOE O 425.1 and DOE-STD-3006-93). 

A recent incident that occurred during a post-turnaround startup at a refining facility was investigated by the U.S. Chemical Safety Board (CSB) and the company involved. Both reports recommendations imply that thorough prestartup safety review implementation could have mitigated or completely avoided the incident. 

---