The Pre-Startup Safety Review (PSSR) Implementation Training Course by British Academy for Training and Development, under the Engineering, Maintenance and Operation Training Courses category and Operations Readiness and Assurance Training Courses specialization, provides a practical framework for conducting effective Pre-Startup Safety Review activities before commissioning, startup, or restart. The course explains PSSR requirements, startup safety principles, risk assessment, compliance controls, and systematic verification of facilities, equipment, procedures, and personnel readiness.

Participants develop the ability to plan, execute, document, and close PSSR activities in line with OSHA expectations and recognized process safety practices. The training focuses on identifying unresolved hazards, verifying safety-critical systems, confirming operating procedures, assessing workforce readiness, and ensuring corrective actions are completed before startup. It supports organizations in strengthening PSSR compliance, reducing operational risk, and achieving a controlled transition into safe operations.

• Understand the principles, purpose, and scope of Pre-Startup Safety Review (PSSR).
• Explain key OSHA requirements related to PSSR and process safety management.
• Develop structured PSSR implementation plans for new and modified facilities.
• Identify hazards and evaluate operational risks before startup.
• Verify equipment, systems, safeguards, and safety-critical controls.
• Assess readiness of operating procedures, maintenance activities, and emergency systems.
• Confirm personnel training and competency before commissioning and startup.
• Develop effective PSSR checklists, documentation, and approval processes.
• Identify, prioritize, and close outstanding corrective actions.
• Strengthen startup safety, operational readiness, and compliance performance.

Target Audience

• Operations and Production Managers
• Process Safety Engineers
• HSE and Safety Professionals
• Commissioning and Startup Engineers
• Maintenance Managers and Engineers
• Operations Readiness and Assurance Professionals
• Project Managers and Project Engineers
• Plant and Facility Managers
• Process Engineers
• Compliance and Risk Management Professionals
• Supervisors involved in commissioning and startup
• Personnel responsible for PSSR implementation and process safety

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