Pre-Startup Safety Review (PSSR): A Comprehensive Guide

In this article:

1. What is a PSSR?

2. Why do industries conduct PSSR?

3. When should a PSSR be conducted?

4. How is a PSSR conducted?

5. Conclusion

   
   

In industrial settings, ensuring readiness for start-up is essential for safety before bringing new equipment or process system online for a first time, or after events such as:

• Modifications or changes to a system, equipment or procedure;

• Emergency shutdown;

• Turnaround;

• Major maintenance activity;

• After major accidents.

Before a process begins operating, it must be carefully reviewed to confirm that it is safe, complete, and functioning as designed and intended. This is the function of a Pre Start-Up Safety Review (PSSR).

This insight explains what a PSSR is, why it is performed, and how the process works.

What is a PSSR?

A PSSR is a structured assurance process to verify that a facility, system, or piece of equipment, is fully prepared for safe operation. While it typically follows a checklist, the process goes beyond simple box-ticking. Its purpose is to confirm that engineering work is complete, all safety systems and controls are in place, and that trained personnel, and proper procedures are ready for safe operation.

This preparedness is evaluated by means of three P’s:

• Plant readiness;

• People readiness;

• Procedural readiness.

Plant readiness includes mechanical completion of all equipment and components, including all associated hardware and control systems. People readiness means completion of all necessary communication, organizational arrangements and training prior to start-up. Procedural readiness involves availability of all process safety information, start-up, normal operation and emergency procedures, and emergency preparedness as well.

By ensuring everything is in order before a system goes live, the PSSR confirms that the workplace is safe for operators, the public, and the environment.

Why do Industries Conduct PSSR?

Industries carry out PSSRs for a range of safety, legal, and operational reasons:

1. Accident Prevention: Industry process safety incident history shows that start-up phases are particularly high-risk time of the lifecycle of process plants. Incomplete installations, incorrect set-ups, missing procedures, failing to communicate content and impact of changes can lead to serious incidents. A PSSR helps catch these issues early;

2. Regulatory and Company Compliance: In the EU, regulations such as the Seveso Directive (Directive 2012/18/EU) require strict safety measures for facilities handling hazardous substances. In addition to legal requirements, many companies have their own internal safety and engineering standards that mandate a PSSR before certain operations begin. Performing the review can ensure external and internal compliance;

3. Quality Control: A successful PSSR ensures that equipment will function as intended, avoiding costly downtime or defective products;

4. Environmental Protection: Ensuring systems like ventilation, waste management, and spill control are functioning protects the environment from unintentional discharges or emissions;

5. Readiness Verification: It confirms that employees are trained, emergency systems are in place, and documentation is complete before operations commence.

When Should a PSSR be Conducted?

A PSSR should be performed before starting up any process that poses potential safety, environmental, or operational risks, especially when changes or significant events have occurred. Common situations that trigger a PSSR include:

• Grassroots facility’s initial start-up: Before the first-time operation of a newly constructed plant or facility to confirm all systems are safely installed and ready;

• Start-up after major turnaround or maintenance activity: When critical equipment or systems have been overhauled, replaced, or significantly maintained during a shutdown;

• After modifications in hardware, software, or key operating procedures: Whenever physical changes, control system updates, or procedural adjustments affect how the process is operated or controlled;

• After major accidents: Following significant safety incidents to verify that corrective actions have been implemented and systems are safe to restart;

• After certain emergency shutdowns: Especially when the shutdown was caused by abnormal or hazardous conditions that could have impacted system integrity;

• After an extended period of suspended operations: If a process or facility has been idle for a long time, conditions may have changed, degraded, or become non-compliant with current standards.

In all these cases, a PSSR ensures that the process is safe, compliant, and fully prepared for restart.

How is a PSSR Conducted?

The process of conducting a PSSR typically follows these steps:

1.      Initiation:

Determine the scope of the PSSR.

2.      Determine Timing:

The timing of the PSSR shall be projected and planned in the project. The PSSR should be scheduled early enough to ensure adequate time for addressing all required areas and implementing any findings that may affect the start-up of the facility, without causing delays. The review process typically takes 1-2 weeks, depending on the project size.

3.      Team Formation:

A multidisciplinary team is assembled, often including representatives from engineering, operations, commissioning team, safety, and quality assurance. Most importantly, this team is led by a PSSR leader who is experienced in managing the PSSR process.

4.      Develop a Terms of Reference (ToR):

The ToR document outlines the scope and conditions for the PSSR. The documentation that will be needed for review in the PSSR will be clearly stated in this document, together with the planned activity and schedule.

5.      Review PSSR Checklist:

The PSSR checklist that will be followed is reviewed. If needed, the checklist should be adapted to address the specific scope of the project. The checklist includes items such as:

• Safety documentation and permits management;

• Mechanical and electrical completion;

• Instrumentation and control systems;

• Emergency response systems;

• Process safety and technology;

• Occupational health & ergonomics;

• Field verification.

6.      Conduct interviews and documentation review:

The PSSR checklist includes questions that are best addressed through discussions with the appropriate personnel. These discussions are led by the PSSR leader. Any required documentation – such as permits, certificates, and other records – must be presented to the PSSR leader as evidence that conditions are met. Together with the team, the PSSR leader will review each item on the checklist. If any issues or gaps are identified, they will be documented along with assigned corrective actions. To keep the meeting efficient, the PSSR leader should share the checklist topics in advance, giving team members time to prepare and gather the necessary materials.

7.      Conduct field inspection/site visit:

The team conducts an on-site walk-through to inspect the installation, verifying equipment labeling, system connections, instrumentation calibration, signage, and other physical elements to ensure they meet the requirements of the PSSR checklist.

8.      Issue PSSR report:

The results and findings are summarized in PSSR report. Any deficiencies found during the PSSR are logged and assigned for correction. The system cannot go live until all critical issues are resolved, though minor findings may be addressed on a follow-up schedule if they do not impact safety or compliance.

9.      Sign-Off and Approval:

Once all elements are reviewed and issues resolved, the PSSR team signs off the review and grants formal approval for startup.

Step-by-Step Procedure for Conducting a PSSR

The PSSR leader holds a central role in ensuring the process is both thorough and effective. An experienced leader understands the technical systems involved, anticipates common pitfalls, and knows when to dig deeper. They coordinate across disciplines, keep the review focused, and ensure the integrity of the findings and recommendations.

Conclusion

A PSSR is a critical step in ensuring that a process, system, or facility is safe and ready to operate. Whether it is the start-up of a new plant, a restart after major maintenance, or a recovery following an incident, the PSSR acts as a final safety checkpoint to catch potential issues. It verifies that equipment is complete, procedures are in place, personnel are prepared, and all regulatory and company standards are met.

While the process is structured and often checklist-driven, its success depends on more than just ticking boxes. The experience, diligence, and coordination skills of the PSSR leader are essential to guiding the review, asking the right questions, and ensuring all findings are addressed. When done properly, a PSSR protects people, assets, and the environment – while reinforcing a company’s commitment to operational safety and readiness.

How ORS Can Help

ORS supports companies by providing experienced leadership for PSSR processes, acting as an independent party to ensure objectivity and thoroughness. ORS can also help with developing and customizing PSSR routines and checklists tailored to the specific operations and regulatory requirements in question. Whether for a new facility or a restart after major changes, our expertise helps ensure your start-up is safe, compliant, and well-prepared.