The Definition of Pre-Startup Safety Review (PSSR)

Definition of Pre-Startup Safety Review (PSSR)

A pre-startup safety review (PSSR) is a final, documented check that a new or significantly modified facility, process or piece of equipment is safe to start up. It confirms that construction and equipment match the design, that safety, operating, maintenance and emergency procedures are in place, that hazards have been reviewed and that workers have been trained.

Under OSHA's Process Safety Management standard, 29 CFR 1910.119(i), a PSSR is required before highly hazardous chemicals are introduced to a new facility or to a modified facility when the modification changes the process safety information. It is closely tied to management of change.

Key Facts About PSSRs

• A process hazard analysis must be done for new facilities, and its recommendations resolved or implemented, before startup.
• PSSR is the gate between construction and operation, so open items must be closed or formally risk-assessed first.
• Typical checklists cover piping and instruments, relief devices, alarms and interlocks, procedures, training and emergency equipment.
• Many incidents happen during startup, when systems and people are working with unfamiliar conditions.
• PSSR is used widely outside PSM-covered sites as a good engineering practice.

Example of a Pre-Startup Safety Review

A refinery replaces a heat exchanger with a larger model. Before reintroducing hydrocarbons, the PSSR team walks down the installation, confirms the new relief valve is set correctly, updates drawings and procedures and verifies operators have been trained on the new controls.

How to Conduct a PSSR

1. Assemble a team with operations, engineering, maintenance and safety representatives.
2. Use a checklist tailored to the project scope.
3. Field-verify equipment against design and process safety information.
4. Confirm procedures, training and emergency arrangements are complete.
5. Document findings, close critical items before startup and get formal sign-off.

Related Terms

• Process Safety Management (PSM)
• Management of Change (MOC)
• Process Hazard Analysis (PHA)
• Overpressure Protection
• Audit (EHS Audit)

Frequently Asked Questions: Pre-Startup Safety Review

When is a PSSR required?

Under PSM, before introducing highly hazardous chemicals into a new facility or a modified facility where the change affects process safety information. Many companies also require PSSRs after major turnarounds.

What is the difference between a PSSR and an MOC?

MOC reviews and approves a change before it is made. PSSR verifies that the change was implemented correctly and is ready to operate before startup.

Can startup proceed with open PSSR items?

Only items that don't affect safe startup, and only if they're documented with owners and due dates. Safety-critical items must be closed first.