Operational Readiness (PSSR)
A pre startup safety review that closes the gap between construction completion and live operation
What this element is and why it matters
Operational Readiness, operationalised as the Pre Startup Safety Review or PSSR, is the final structured check before highly hazardous chemicals are introduced into the process. The element maps to OSHA 1910.119(i) and verifies that construction and installation match the design, that every PSM element applicable to the new or modified process is in place, that PHA recommendations have been closed or formally risk accepted, and that operators have been trained on the updated procedures. Our team runs this gate so the last check before startup carries real weight.
Individual significance for organisations
PSSR is the last opportunity to catch the post modification incident pattern before it shows up in operation. Sites with disciplined PSSR programmes achieve dramatically lower startup incident rates. The CSB reports for Williams Olefins, Tesoro Anacortes, and BP Texas City all included PSSR findings, incidents that happened because the formal gate was either never held or held without substance.
Contribution to Risk Based Process Safety (RBPS)
PSSR is the closing gate for MOC (Element 13) and the opening gate for live Operating Procedures (Element 8) and Conduct of Operations (Element 15). It verifies Asset Integrity (Element 10) commissioning, Training (Element 12) completion, PHA action closure (Element 7), and procedure currency (Element 8). PSSR is the integration point where the entire management system proves it is ready for operation.
What compliant execution looks like
How we implement this element
A focused six step methodology calibrated to deliver operational readiness (pssr) as a working capability rather than a documented compliance artefact.
We define the PSSR scope per OSHA PSM (i) across new construction, MOC driven modification, and post turnaround restart, aligned with your corporate PSSR procedure.
We run a multi discipline walk down across process, mechanical, electrical, instrumentation, and HSE, verify that construction matches the P&ID, and document deviations and their resolution.
We confirm that every PHA, HAZOP, LOPA, and SIL action related to the change is closed or risk accepted with documented evidence, aligned with the PHA register.
We verify that operating procedures are updated to reflect the change, that operator training is complete with documented competency, and that the emergency response procedure is aligned.
We confirm mechanical integrity signoff with relief sized and vessels coded, the safety instrumented system commissioned through factory and site acceptance testing, hazardous area classification drawings issued, and the emergency shutdown and fire and gas systems commissioned.
We obtain site leader and HSE manager signoff before chemicals are introduced, and specify the authorisation hierarchy and audit trail.
Element implementation flow chart
A decision gated workflow that shows the actual sequence of activities from initiation through steady state operation, with key decision points highlighted.
What we produce
- A PSSR scope and procedure
- A multi discipline walk down protocol and checklist
- A PHA action close out verification record
- A procedure and training verification register
- A mechanical integrity, instrumented system, and area classification commissioning signoff
- A leadership signoff authorisation record
Where execution fails
- A PSSR run as a checklist without the depth of a real field walk down
- PHA actions still open at PSSR and risk accepted without justification
- Operator training certified on paper but never field verified
- Leadership signoff delegated without an informed decision behind it
Codes this element is built on
Explore related elements in this framework
Risk Based Process Safety (RBPS) full element index
Talk to us about implementing Operational Readiness (PSSR)
We can scope this element implementation against your facility, regulatory context, and existing management system maturity, then integrate it with the other Risk Based Process Safety (RBPS) elements you already operate.