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Pre-Startup Safety Review (PSSR) Checklist

A comprehensive checklist used to verify safety measures and operational readiness before starting up new or modified equipment, processes, or facilities in industrial settings.

Pre-Startup Safety Review (PSSR) Checklist

by: audit-now
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About This Checklist

A Pre-Startup Safety Review (PSSR) Checklist is a crucial tool in ensuring the safe and efficient startup of new or modified equipment, processes, or facilities. This comprehensive checklist helps identify and mitigate potential hazards before operations begin, reducing the risk of accidents, injuries, and costly downtime. By systematically reviewing all aspects of safety, from equipment integrity to personnel training, the PSSR Checklist plays a vital role in maintaining workplace safety, regulatory compliance, and operational excellence.

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Industry

Manufacturing

Standard

OSHA PSM 1910.119

Workspaces

Pharmaceutical production facility
Industrial Plants
Chemical Processing Facilities
Manufacturing Facilities

Occupations

Safety Manager
Process Engineer
Operations Manager
Maintenance Supervisor
Quality Assurance Specialist
1
Have all potential hazards associated with the new or modified equipment been identified?
2
Is the equipment operationally ready for startup?
3
What is the current temperature of the equipment?
Min: 0
Target: N/A
Max: 100
4
Is the equipment compliant with relevant regulatory standards?
5
Is the emergency shutdown system fully operational?
6
Have all start-up procedures been reviewed and understood by the team?
7
When was the last safety training conducted for the team?
8
Are all team members wearing the required personal protective equipment?
9
Has a Process Hazard Analysis (PHA) been completed for the new equipment?
10
Provide details of any management of change (MOC) documentation related to the equipment.
11
What is the testing frequency of the Safety Instrumented System?
Min: 1
Target: N/A
Max: 365
12
Have all relevant stakeholders been informed about the new process?
13
Have all necessary risk mitigation measures been implemented before startup?
14
What comments or observations were noted during the pre-startup review?
15
How many emergency equipment checks have been performed?
Min: 0
Target: N/A
Max: 100
16
When was the last maintenance performed on the equipment?
17
Is all necessary safety equipment available and accessible for the startup?
18
Summarize the key points discussed during the startup team briefing.
19
How many items are completed on the final startup checklist?
Min: 0
Target: N/A
Max: 50
20
Has the lockout/tagout procedure been verified before startup?

FAQs

A PSSR should be conducted before the initial startup of new facilities, equipment, or processes, and before restarting modified equipment or processes that have undergone significant changes.

The PSSR team typically includes representatives from operations, maintenance, engineering, safety, and management. Subject matter experts may also be involved depending on the specific equipment or process being reviewed.

A PSSR Checklist typically covers areas such as equipment integrity, process safety information, operating procedures, training, emergency response, management of change, and regulatory compliance.

The PSSR Checklist is an integral part of process safety management, ensuring that all safety systems and procedures are in place and functioning correctly before startup, thereby preventing potential incidents and maintaining safe operations.

Yes, while there are common elements, a PSSR Checklist can and should be customized to address the specific hazards, equipment, and regulatory requirements of different industries or processes.

Benefits of Pre-Startup Safety Review (PSSR) Checklist

Ensures all safety measures are in place before startup

Reduces the risk of accidents and injuries

Promotes regulatory compliance and operational excellence

Identifies potential hazards and mitigation strategies

Enhances overall workplace safety culture