Pre-Startup Safety Reviews

A Pre-Startup Safety Review (PSSR) is a critical safety and compliance process conducted before the initial startup or restart of any facility, process system, or piece of equipment. Its primary objective is to verify the readiness and integrity of installations, confirm that all safety systems are operational, and ensure that personnel are trained and procedures are in place. PSSR is a crucial component of process safety management (PSM), designed to prevent incidents, minimize startup risks, and meet regulatory and corporate safety standards. Whether launching a new project, completing a major modification, or restarting after a shutdown, a well-executed PSSR ensures a safe, smooth, and compliant transition to operational status. At Ifluids Engineering, we provide end-to-end support for Pre-Startup Safety Reviews (PSSR) to help clients ensure a safe, compliant, and incident-free startup. Our structured approach combines technical expertise, field experience, and regulatory insight to deliver thorough, efficient, and actionable reviews.

PSSR Objectives 

The objectives of PSSR are to verify:

  • Construction and Equipment compliance with design specifications. 
  • Hazard Analysis and Risk Assessments are conducted for new and/or modified facilities, addressing recommendations from the Process Hazard Analysis (PHA) through implementation.
  • Availability and adequacy of HSE, relevant procedures, and emergency response documentation.
  • Training completion for relevant personnel.
  • Compliance of modified facilities with Management of Change (MOC) requirements

PSSR Trigger Events

  • For any Facility, Installation, Equipment, or system installed as part of a project or developmental activity
  • For any Change or modification to the existing Facility, Installation, Equipment, or system
  • Completion of Turnarounds and major non-routine maintenance
  • Startup of a Facility, Installation, or equipment after an extended Shutdown or preservation, mothballed condition, or a major incident.

What are the key elements of a PSSR checklist?

Common elements include:

  • Mechanical completion and system integrity
  • Instrumentation and controls
  • Safety systems and emergency shutdown
  • Operating procedures and manuals
  • Training and competency of personnel
  • Permits and regulatory approvals
  • Hazard analysis closure

Conducting a PSSR

An independent PSSR Team Leader shall be experienced in projects/operations/engineering with a minimum of 10 years of relevant experience.

Illustration of Pre-Startup Safety Review (PSSR) process flowchart illustrating key steps including PSSR requirement identification, team formation, checklist preparation, documentation review, walkthrough, issue logging, corrective actions, action verification, certification, and system startup readiness.
PSSR Process Flowchart: Step-by-Step Pre-Startup Safety Review Procedure
  • Initiate a PSSR by convening a meeting with Discipline Engineers and form a team with relevant Subject Matter Experts
  • The PSSR team schedules and conducts meetings to prepare and finalize the Terms of Reference as appropriate.
  • The PSSR team identifies, gathers, and organizes documentation to review and verify during site visits.
  • During the site visits, the PSSR team shall verify and record applicable comments in the form of a checklist(s)
  • The PSSR team identifies and records pre-startup and post-startup actions required.
  • Post site verification exercise, the PSSR Team Leader organizes a close-out meeting to ensure all aspects of a safe startup have been thoroughly checked by the team.
  • The prepared report on PSSR shall be approved by the PSSR Team Leader before the startup.
  • The PSSR team shall schedule and conduct meetings to monitor the progress for the close-out of critical issues
  • Following the confirmation on implementation and close-out of all pre-startup action items, a ‘Ready for Startup’ (RFSU) certificate shall be signed off and issued by the PSSR Team Leader.

Relevant PSSR Standards

  1. OSHA 29 CFR 1910.119 – Process Safety Management (PSM)
  2. API Recommended Practice 75 – Safety and Environmental Management System (SEMS)
  3. ISO 45001 – Occupational Health and Safety Management Systems
  4. NFPA 56 – Standard for Fire and Explosion Prevention During Cleaning and Purging of Flammable Gas Piping Systems
  5. Center for Chemical Process Safety (CCPS)

Why Choose iFluids Engineering and Consultancy WLL for PSSR?

  • Multidisciplinary experts with deep industry knowledge
  • Methodology aligned with OSHA, ISO 45001, and project commissioning standards
  • Integration with safety lifecycle processes