Pre-Startup Safety Review (PSSR) Implementation Training Course

Module 1: Fundamentals of Pre-Startup Safety Review

• Definition and purpose of PSSR
• PSSR within operations readiness and assurance
• Key stages of the startup lifecycle
• Relationship between commissioning, startup, and PSSR
• PSSR roles, responsibilities, and accountability

Module 2: OSHA and PSSR Compliance Requirements

• Overview of OSHA process safety requirements
• PSSR requirements under Process Safety Management
• Compliance responsibilities and documentation
• Management of change and PSSR integration
• Regulatory expectations and common compliance gaps

Module 3: PSSR Planning and Preparation

• Developing a PSSR implementation strategy
• Defining review scope and boundaries
• Establishing PSSR teams and responsibilities
• Preparing review schedules and checklists
• Gathering technical and operational documentation

Module 4: Risk Assessment and Hazard Verification

• Pre-startup hazard identification
• Process hazard analysis review
• Risk assessment methodologies
• Safety-critical equipment verification
• Identification of unresolved hazards and deficiencies
• Risk-based prioritization of corrective actions

Module 5: Facility, Equipment, and System Readiness

• Mechanical completion and equipment readiness
• Inspection and testing requirements
• Instrumentation and control system verification
• Safety and emergency systems
• Utilities and support systems
• Alarm, interlock, and protective system verification

Module 6: Procedures, Training, and Operational Readiness

• Operating and maintenance procedure verification
• Emergency response procedures
• Personnel training and competency requirements
• Contractor readiness and communication
• Shift organization and operational responsibilities
• Confirming workforce readiness for startup

Module 7: Conducting and Documenting the PSSR

• PSSR execution methodology
• Review meetings and field verification
• PSSR checklists and evidence collection
• Recording findings and deficiencies
• Action tracking and responsibility assignment
• Documentation and approval requirements

Module 8: Corrective Actions and Startup Authorization

• Classification of PSSR findings
• Corrective action management
• Verification and closure of outstanding actions
• Escalation of critical safety issues
• Final PSSR approval
• Startup authorization and handover

Module 9: Practical PSSR Implementation

• PSSR case studies and scenarios
• Simulated pre-startup safety reviews
• Risk assessment exercises
• Checklist development exercises
• Corrective action tracking
• Lessons learned and continuous improvement