Overview
Pre-startup safety review is a formal barrier between construction or modification work and the introduction of process hazards. A PSSR team should compare as-built equipment with the design, confirm safety-critical devices and procedures, close or risk-assess outstanding items, and verify that affected operators have been trained. For US OSHA PSM-covered processes, 29 CFR 1910.119(i) sets specific PSSR conditions; other jurisdictions and project contracts may differ. This guide does not authorize energization or chemical introduction: the operating authority must sign off a site-specific PSSR.
Main Hazards
- • Safety-critical relief, interlock or alarm installed incorrectly or not tested
- • Open mechanical completion items carried into commissioning without risk evaluation
- • Operators untrained on revised equipment, operating limits and emergency response
- • Unresolved temporary blinds, jumpers, supports or isolations
- • As-built P&IDs or equipment lists differing from site installation
- • Simultaneous construction and start-up affecting adjacent teams
Essential Controls
- 1Define the PSSR boundary, responsible operations authority and exact startup hold point.
- 2Compare as-built P&IDs, equipment tags, design requirements and installed protective devices.
- 3Verify relief devices, shutdown systems, instruments and alarms through documented acceptance tests.
- 4Review every open item with accountable owner; critical safety items must be resolved before authorization.
- 5Confirm current operating, maintenance, emergency and isolation procedures are accessible and understood.
- 6Check that affected operators, maintenance and contractors received training appropriate to changed risks.
- 7Record PSSR findings and obtain formal operations sign-off before introducing hazardous energy or chemicals.
Common Mistakes
- ×Treating the construction punch list as equivalent to a safety review.
- ×Closing findings administratively without physical field verification.
- ×Starting process operations while protection-device testing is incomplete.
- ×Using another facility's PSSR limits without checking local legal and project requirements.
Field verification and hold points
- ✓Equipment and line tags match approved as-built design
- ✓Safety-critical protective functions passed documented testing
- ✓Operating and emergency procedures and training are complete
- ✓Open items were dispositioned and critical findings resolved
- ✓Operations startup authorization is documented
Stop-work decision and escalation
Do not introduce energy or chemicals if safety-critical findings, commissioning boundaries, unresolved isolations or competence gaps remain. Return the package to the responsible PSSR authority.
Technical References
OSHA links lead to official US regulations. Always confirm local legal requirements, scope of applicability, and site-specific procedures. Other listed sources remain informational references until their official links are verified.
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