Maintenance Management
What is PSSR?
PSSR, or Pre-Start Safety Review, is a process used to identify and assess potential hazards and risks associated with equipment or a process before it is started up or put into operation.
It is the systematic review of the design, construction, and installation of the facility or equipment to identify any potential safety issues. It also involves testing and inspection facilities and equipment to verify all relevant safety standards and requirements are met.
A brief history of PSSR
The concept of PSSR has evolved over time in response to the need for the safe operation of facilities and equipment.
In the early 20th century, as industries began to grow and expand, there was an increased focus on ensuring the safety of workers and equipment.
This led to the development of various safety standards and regulations, which established guidelines for the design, construction, and operation of facilities and equipment.
In the latter part of the 20th century, as the complexity of facilities and equipment increased, the need for more comprehensive safety reviews also grew.
This led to the development of PSSR as a formal process for ensuring the safety of facilities and equipment before they are put into operation.
Today, PSSR is an essential part of the commissioning process for new facilities and equipment and is also used when existing facilities and equipment are being modified or reactivated after a period of inactivity.
Learn how you can centrally manage maintenance and sustainability across portfolios
PSSR safety standards and regulations
PSSR is not a regulatory requirement in and of itself. However, there are various regulations and standards that are relevant to PSSR, depending on the specific facility or equipment being reviewed and the location of the facility.
In the United States, the Occupational Safety and Health Administration (OSHA) is responsible for regulating and enforcing safety standards in the workplace. OSHA, for instance, has issued specific standards related to PSSR for certain types of equipment, such as cranes and hoists.
OSHA's standard for cranes and derricks in construction (29 CFR 1926.550) requires that a PSSR be conducted before the initial use of a crane and at least annually thereafter. The standard for hoists (29 CFR 1910.179) requires a PSSR before the initial use of a hoist and at least annually thereafter or when the hoist has been altered or repaired.
In addition to OSHA, there may be other regulatory agencies or organizations that have jurisdiction over specific types of facilities or equipment.
For example, the Environmental Protection Agency (EPA) regulates the handling and disposal of hazardous materials, the National Fire Protection Association (NFPA) has standards for the installation and maintenance of fire protection systems, and American Petroleum Institute (API) has published guidelines for PSSR in the oil and gas industry.
Other countries may have their own regulatory agencies and standards that are relevant to PSSR. For example, in the European Union, CE marking is a requirement for many products, including construction products, machinery, and medical devices. The CE marking indicates that the product meets the relevant safety, health, and environmental protection requirements.
It is important for companies to be familiar with the relevant safety standards and regulations that apply to their equipment and processes and to ensure that their PSSR processes are in compliance with those standards.
Advantages of performing PSSR
There are several advantages to performing Pre-Start Safety Review (PSSR) on equipment or processes:
- Improved safety: A PSSR helps identify and assess potential hazards and risks associated with equipment or processes, which can help prevent accidents and injuries.
- Minimized equipment damage: By identifying and addressing potential hazards and risks before equipment is started up or put into operation, PSSR can help minimize the potential for equipment damage.
- Improved efficiency and productivity: PSSR can help identify opportunities for improving the design and operation of equipment or processes, which can lead to increased efficiency and productivity.
- Enhanced compliance: PSSR can help ensure that equipment or processes meet relevant safety standards and regulations, which can help prevent costly fines and legal issues.
- Improved reputation: A strong focus on safety can enhance a company's reputation and improve customer and employee confidence in the organization.
- Reduced costs: By preventing accidents and equipment damage, PSSR can help reduce the costs associated with lost productivity, repairs, and insurance claims.
- Improved communication: PSSR can help facilitate communication between different departments and stakeholders, which can improve overall safety performance.
Suggested reads:
How to perform Facilities Condition Assessment?
A Quick Guide to Avoid Getting Pencil Whipped!
What is a PSSR inspection?
A PSSR inspection is a thorough review of a piece of equipment or system to ensure that it is safe to operate.
This typically involves a detailed examination of the equipment and its components, as well as a review of any relevant documentation, such as O&M manuals, and maintenance records.
The purpose of a PSSR inspection is to identify any potential hazards or defects that could pose a risk to workers or the equipment itself and to take appropriate corrective action to address these issues.
Steps to conduct PSSR inspections
Follow these simple steps to conduct a thorough PSSR inspection:
- Gather all relevant documentation, including operating instructions, maintenance records, and any other relevant information.
- Identify the equipment or system to be inspected and determine the scope of the inspection.
- Review the documentation and familiarize yourself with the equipment or system.
- Inspect the equipment or system thoroughly, paying attention to all components and systems. Look for any visible defects or damage, and check for the proper functioning of controls and safety features.
- Make a list of any issues or defects that are identified during the inspection.
- Determine the appropriate corrective action for any identified issues or defects. This may include repairing or replacing damaged components, updating documentation, or modifying procedures.
- Document the inspection and any corrective actions are taken.
- Review the inspection results with relevant personnel, including maintenance and operations staff.
- Follow up to ensure that any identified issues or defects have been properly addressed.
It is important to follow established procedures and guidelines when conducting a PSSR inspection and to involve qualified personnel as needed to ensure the safety and reliability of the equipment or system.
What is a PSSR walk?
A PSSR walk is a visual inspection of the equipment or system that is performed while it is in operation.
This allows the inspector to observe the equipment in action and identify any potential hazards or issues that may not be evident during a static inspection.
A PSSR walk may also involve testing equipment controls and emergency shutdown procedures to ensure that they are functioning properly.
Steps to conduct a PSSR walk
- Review the design and operation of the equipment or process: Before conducting the PSSR walk, it is important to review the design and operation of the equipment or process. This may include reviewing technical drawings, manuals, and other relevant documentation.
- Assemble a team: It is important to involve all relevant stakeholders in the PSSR walk, including operators, maintenance personnel, and safety and health personnel.
- Use a standardized PSSR checklist: Use a checklist to ensure that all necessary items are covered during the PSSR walk. The checklist should be tailored to the specific equipment or process being reviewed.
- Conduct walk-throughs: Start at the beginning of the equipment or process and work through it step by step, looking for any potential hazards and risks. Use visual aids, such as diagrams and photographs, to help identify potential hazards and risks.
- Identify and assess potential hazards and risks: As you conduct the walk-through, make a list of any potential hazards and risks that you identify. Assess the likelihood and severity of each hazard and risk, and determine what controls are necessary to mitigate them.
- Implement controls: Implement any necessary controls to mitigate the identified hazards and risks. This may include installing guards, installing warning signs, or implementing procedures to ensure safe operation.
- Document and communicate findings: Document the findings of the PSSR walk and communicate them to all relevant stakeholders. This will ensure that everyone is aware of the potential hazards and risks associated with the equipment or process.
- Review and update the PSSR: The PSSR process should be reviewed and updated regularly to ensure that it is effective in identifying and mitigating potential hazards and risks.
The PSSR walk is an important step in the PSSR process, as it allows the team to identify any potential safety issues that may need to be addressed before the facility or equipment is put into operation.
The PSSR walk also helps to verify that the facility or equipment meets all relevant safety standards and requirements.
After the PSSR walk, the team will typically document any findings or recommendations in a report, which can be used to guide the start-up and operation of the facility or equipment.
The PSSR walk is an important tool for ensuring the safety of facilities and equipment before they are put into operation and helps to prevent accidents or injuries.
Get a free copy of The Property Operations Leader’s Guide for Today’s New Digital Normal!
What is a PSSR checklist?
A PSSR checklist is a tool that is used to ensure that all necessary steps are taken, and all relevant issues are considered during a Pre-Start Safety Review (PSSR).
The checklist typically includes a list of tasks or items that need to be reviewed or checked during the PSSR process.
The content of a PSSR checklist will depend on the specific facility or equipment being reviewed, as well as the relevant safety standards and regulations.
Common items that are included on a PSSR checklist
- Review design and construction documents: This may include reviewing plans and drawings, as well as verifying that all necessary approvals and permits have been obtained.
- Inspection the facility or equipment: This may include a visual inspection of the facility or equipment to identify any potential hazards or defects.
- Test the facility or equipment: This may include functional testing of the facility or equipment to ensure that it is operating correctly and safely.
- Train the right personnel: This may include providing training to personnel who will be involved in the start-up and operation of the facility or equipment.
- Develop procedures and protocols: This may include developing procedures for safely starting up and operating the facility or equipment, as well as protocols for maintenance management and emergency situations.
Tips to improve your PSSR process
The PSSR process in every organization differs depending on the industry, and facilities and equipment being reviewed.
There are, however, some common tips you can use to improve the PSSR process irrespective of the industry or use case:
- Involve all relevant stakeholders: It is important to involve all relevant stakeholders in the PSSR process, including operators, maintenance personnel, and safety and health personnel. This will ensure that all potential hazards and risks are identified and assessed.
- Use a standardized checklist: Using a standardized checklist can help ensure that all necessary items are covered during the PSSR process. The checklist should be tailored to the specific equipment or process being reviewed.
- Use visual aids: Visual aids, such as diagrams and photographs, can be helpful in identifying potential hazards and risks.
- Conduct walk-throughs: A walk-through of the equipment or process can help identify potential hazards and risks that may not be obvious from a desk review.
- Test and verify controls: It is important to test and verify that any controls that have been put in place to mitigate identified hazards and risks are effective.
- Document and communicate findings: It is important to document the findings of the PSSR process and communicate them to all relevant stakeholders. This will ensure that everyone is aware of the potential hazards and risks associated with the equipment or process.
- Review and update the PSSR regularly: The PSSR process should be reviewed and updated regularly to ensure that it is effective in identifying and mitigating potential hazards and risks.
Ensure PSSR compliance with a CaFM
CaFM (Computer-Aided Facility Management) software is a tool designed to help organizations manage and maintain their facilities and assets.
It can be used to help with PSSR (Pre-Start Safety Review) inspections by providing a centralized platform for scheduling and conducting inspections, as well as tracking the status of any identified issues or defects
Some ways that CaFM software helps with PSSR include:
- Scheduling inspections: CaFM software can be used to schedule PSSR inspections and ensure that they are conducted on a regular basis.
- Documenting inspections: CaFM software can be used to document the results of PSSR inspections, including any identified issues or defects and the corrective actions taken.
- Tracking the status of issues and defects: CAFM software can be used to track the status of any issues or defects that are identified during PSSR inspections, including whether they have been repaired or are still in progress.
- Providing alerts and notifications: CaFM software can be configured to send alerts and notifications to relevant parties when PSSR inspections are scheduled or when issues or defects are identified, helping to ensure that all parties are aware of any necessary actions.
- Customizable inspection templates: CaFM software can provide customizable templates for conducting PSSR inspections, allowing organizations to ensure that all relevant aspects of the equipment or system are examined.
- Photo and video documentation: CaFM software can allow users to capture and attach photos and videos to PSSR inspection reports, providing a visual record of any identified issues or defects.
- Electronic signatures: CaFM software can support electronic signatures, allowing users to sign off on PSSR inspection reports remotely, reducing the need for physical paperwork.
- Real-time reporting: CaFM software can provide real-time reporting on the status of PSSR inspections, including any identified issues or defects, helping to ensure that all parties are aware of the current status of the inspection process.
By using CaFM software to manage PSSR inspections, organizations can improve the inspection process efficiency and ensure that all identified issues and defects are properly addressed.
