Pre-startup Safety Reviews (PSSRs) play a vital role in ensuring that new processes or modifications are safely integrated into operations, protecting personnel, the environment, and the organization’s reputation while fostering continuous improvement and compliance with regulatory standards.
Conducting PSSRs in pipeline asset structures is particularly challenging due to the complexity of pipeline systems, remote locations, variability in pipeline contents, regulatory compliance requirements, environmental considerations, third-party interactions, safety culture, and emergency preparedness. Overcoming these challenges requires careful planning, coordination, and adherence to rigorous safety standards and protocols.
Whether starting up a single piece of equipment or an entire facility, the PSSR ensures that all necessary safety controls are in place and that any outstanding issues are addressed.
An effective PSSR process not only protects personnel and assets but also promotes operational readiness and regulatory compliance. However, improving the efficiency of PSSRs—without compromising their thoroughness—is a persistent challenge, especially during complex Management of Change (MOC) projects.
MOC: One Project, Multiple PSSRs
In practice, a single MOC often requires multiple PSSRs. For example, you might conduct an initial PSSR to start up supporting utilities such as steam, nitrogen, or compressed air systems, followed by a separate PSSR for the actual process equipment. Each stage requires careful, detailed verification. Without clear processes, these layered PSSRs can become sources of confusion, delay, and risk.
Key Challenges in PSSR Processes
- Complexity of Checklists:
PSSRs typically involve comprehensive checklists covering safety systems, equipment readiness, operating procedures, training, and emergency response plans. Poorly designed checklists can lead to ambiguity or missed critical items. - Capturing Action Items:
Identifying deficiencies during a PSSR is only half the battle. It’s vital to record follow-up actions, assign ownership, and track closure to ensure the facility is safe for operation. - Field Execution Barriers:
In many industrial environments, Wi-Fi or cellular data may be unavailable. This forces field personnel to rely on paper-based forms, which later must be transcribed into electronic systems—creating opportunities for errors and administrative delays. - Record Retention:
A completed PSSR must be tied to its associated MOC and retained for the life of the facility. Poor document control jeopardizes both compliance and institutional knowledge.
Best Practices for Improving PSSR Efficiency
1. Streamline and Standardize Checklists
- Customize checklists by equipment type or project scope to avoid irrelevant questions.
- Use logic-driven forms that adapt based on responses (e.g., if a system is not applicable, follow-up questions can be automatically skipped).
- Periodically review and update checklists based on lessons learned from previous startups and incidents.
2. Integrate Action Item Management
- Ensure the PSSR process includes real-time creation, assignment, and tracking of action items.
- Where possible, manage action items in a fully integrated PSM platform such as the FACILEX® Risk-Based Process Safety Suite.
- Require responsible individuals to acknowledge and complete actions with electronic signatures for accountability.
3. Enable Field Flexibility: Paper and Electronic Options
- Provide fillable paper forms for locations without internet access, but design processes for quick transcription into a fully integrated PSM system platform immediately after fieldwork.
- Equip field personnel with tablets or rugged laptops when possible, using offline-capable software that syncs automatically when connectivity is restored.
- Prioritize user-friendly interfaces to reduce administrative burden on safety professionals.
4. Implement a Fully Integrated PSM Platform
- All PSSRs must be stored within the MOC record and cross-referenced with associated PHA studies, mechanical integrity documentation, and operator training records.
- Implement a fully integrated PSM platform with robust search and retrieval capabilities, ensuring that PSSRs are accessible for audits, incident investigations, and facility changes many years after completion.
- Regularly back up digital PSSR records and ensure they meet legal retention requirements.
Conclusion
The PSSR is a non-negotiable step toward safe, compliant operations—but that doesn’t mean it must be slow or cumbersome. By standardizing checklists, improving action item tracking, enabling flexible field execution, and maintaining excellent records, organizations can significantly improve the efficiency of their PSSRs while maintaining the rigor necessary to protect people, property, and the environment. A fully integrated PSM platforms like FACILEX® delivers all the elements needed to make these improvements sustainable and scalable.
