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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 Process Safety Management (PSM) Standard 29 CFR 1910.119

Workspaces

Manufacturing plant
Chemical processing facility
Oil refinery
Pharmaceutical production facility

Occupations

Safety Manager
Process Engineer
Operations Manager
Maintenance Supervisor
Quality Assurance Specialist

Pre-Startup Safety Review Checklist

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1
Is the equipment compliant with relevant regulatory standards?

Select the compliance status.

Ensuring regulatory compliance is critical for legal operation and safety.
2
What is the current temperature of the equipment?

Enter the temperature in degrees Celsius.

Monitoring temperature is crucial for safe operation and to prevent equipment failure.
Min: 0
Target: N/A
Max: 100
3
Is the equipment operationally ready for startup?

Confirm if the equipment is operationally ready.

Operational readiness ensures that all systems are functional and safe for operation.
4
Have all potential hazards associated with the new or modified equipment been identified?

Select the hazard identification status.

Identifying hazards is essential to ensure safety and compliance with process safety management.
5
Are all team members wearing the required personal protective equipment?

Confirm if all personnel are wearing PPE.

Ensuring PPE compliance is vital for the safety of individuals involved in the startup process.
6
When was the last safety training conducted for the team?

Enter the date of the last safety training.

Regular safety training is essential for maintaining awareness of safety protocols and procedures.
7
Have all start-up procedures been reviewed and understood by the team?

Provide details of the start-up procedure review.

Reviewing start-up procedures ensures that all team members are aware of their roles and responsibilities, enhancing safety.
8
Is the emergency shutdown system fully operational?

Select the status of the emergency shutdown system.

An operational emergency shutdown system is critical for immediate response to hazardous situations.
9
Have all relevant stakeholders been informed about the new process?

Confirm if stakeholders have been informed.

Effective communication with stakeholders ensures alignment and preparedness for the new process.
10
What is the testing frequency of the Safety Instrumented System?

Enter the testing frequency in days.

Regular testing of safety systems is necessary to ensure their proper functioning during emergencies.
Min: 1
Target: N/A
Max: 365
11
Provide details of any management of change (MOC) documentation related to the equipment.

Detail any MOC documentation.

MOC documentation is crucial for ensuring that any changes are properly assessed and communicated.
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12
Has a Process Hazard Analysis (PHA) been completed for the new equipment?

Select the PHA completion status.

A completed PHA is essential to identify and mitigate risks associated with hazardous processes.
13
When was the last maintenance performed on the equipment?

Enter the date of the last maintenance.

Maintaining equipment is essential to ensure its safe operation and prevent failures during startup.
14
How many emergency equipment checks have been performed?

Enter the number of emergency equipment checks.

Regular checks of emergency equipment ensure readiness in case of an emergency during startup.
Min: 0
Target: N/A
Max: 100
15
What comments or observations were noted during the pre-startup review?

Provide any comments or observations.

Documenting comments from the pre-startup review helps identify areas for improvement and follow-up actions.
16
Have all necessary risk mitigation measures been implemented before startup?

Select the status of risk mitigation measures.

Implementing risk mitigation measures is crucial to prevent incidents during startup operations.
17
Has the lockout/tagout procedure been verified before startup?

Confirm if the lockout/tagout procedure has been verified.

Verifying lockout/tagout procedures is critical to prevent accidental energization of equipment.
18
How many items are completed on the final startup checklist?

Enter the number of completed checklist items.

Tracking the completion of checklist items ensures that all necessary steps are taken before startup.
Min: 0
Target: N/A
Max: 50
19
Summarize the key points discussed during the startup team briefing.

Provide a summary of the startup team briefing.

A briefing ensures that the team is aligned and aware of the startup plan and safety considerations.
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20
Is all necessary safety equipment available and accessible for the startup?

Select the availability status of safety equipment.

Ensuring the availability of safety equipment is critical for a safe startup operation.

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

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