A rushed or incomplete startup review is one of the most common root causes behind incidents in the first weeks of plant operation. The PSSR Execution and Startup Risk Control Training Course, offered by the Arab British Fellowship Training Academy under the Engineering, Maintenance and Operation Training Courses category and the Operations Readiness and Assurance Training Courses specialization, equips participants with a hands-on method for closing that gap — verifying that equipment, procedures, and people are genuinely ready before a facility is commissioned, restarted, or handed over.

Rather than treating PSSR as a paperwork exercise, the course walks through how to plan a review, uncover hazards that were missed earlier in the project, confirm that safety-critical systems and trained personnel are in place, and track corrective actions to closure in line with OSHA expectations and recognized process safety practice. Graduates leave with a repeatable framework for reducing startup risk and supporting a controlled transition into safe operations.

• Explain why unresolved hazards during startup lead to incidents, and where PSSR fits within operations readiness and assurance.
• Interpret OSHA process safety management requirements relevant to PSSR and compliance documentation.
• Plan a PSSR review: define scope, build the review team, and prepare checklists and schedules.
• Identify unresolved hazards and evaluate operational risk before startup, including safety-critical equipment and safeguards.
• Verify that operating procedures, maintenance activities, and emergency systems are ready for commissioning.
• Confirm personnel training, competency, and contractor readiness ahead of startup.
• Conduct the review in the field, collect evidence, and document findings and deficiencies.
• Classify findings, prioritize corrective actions, and track them through to closure.
• Support startup authorization decisions with a defensible, evidence-based PSSR record.

Target Audience

• Operations, Production, and Plant/Facility Managers
• Commissioning and Startup Engineers
• Process Safety Engineers and Process Engineers
• HSE and Safety Professionals
• Maintenance Managers and Engineers
• Operations Readiness and Assurance Professionals
• Project Managers and Project Engineers
• Compliance and Risk Management Professionals
• Supervisors and personnel responsible for commissioning, startup, and PSSR implementation

Module 1: Why PSSR Matters — Startup Incidents and Risk Exposure

• Common causes of startup-related incidents
• Where PSSR sits in the operations readiness lifecycle
• Consequences of a rushed or skipped review
• Relationship between commissioning, startup, and PSSR
• Roles, responsibilities, and accountability of the review team

Module 2: Regulatory Foundations — OSHA and Process Safety Management

• Overview of OSHA process safety requirements
• PSSR obligations under Process Safety Management
• Management of change and its link to PSSR
• Compliance responsibilities and documentation
• Common regulatory gaps and how to avoid them

Module 3: Planning the Review — Scope, Schedule, and Documentation

• Defining review scope and boundaries
• Preparing PSSR schedules and checklists
• Gathering technical and operational documentation
• Aligning the review plan with project and commissioning schedules

Module 4: Hazard Identification and Risk-Based Verification

• Pre-startup hazard identification
• Process hazard analysis review
• Risk assessment methodologies
• Verifying safety-critical equipment and safeguards
• Prioritizing corrective actions by risk level

Module 5: Facility, Equipment, and System Readiness

• Mechanical completion and equipment readiness
• Inspection, testing, and instrumentation verification
• Alarm, interlock, and protective system checks
• Utilities and support systems

Module 6: People and Process Readiness

• Operating and maintenance procedure verification
• Emergency response procedures
• Personnel training, competency, and contractor readiness
• Shift organization and workforce readiness for startup

Module 7: Conducting, Documenting, and Closing the PSSR

• PSSR execution methodology and field verification
• Recording findings and deficiencies
• Classifying findings and managing corrective actions
• Escalating critical safety issues
• Final approval and startup authorization

Module 8: Practical Application — PSSR Case Studies

• Simulated pre-startup safety reviews
• Risk assessment and checklist development exercises
• Corrective action tracking practice
• Lessons learned and continuous improvement