Pre Start-up Safety Checks – Trust Us, It’s Worth the Effort

We’ve all been there — a piece of equipment or process has been modified, upgraded, or maybe even just tweaked. It looks ready to go. The instinct? Start it up and get back to work. 

But here’s the thing: jumping straight into operation without a proper pre start-up safety check (PSSC) can be a costly mistake — even when the change seems minor.  It doesn’t matter if it’s a modified process plant, technology protype or even a fighter jet, the overall objectives of the checks are the same.  Note that these checks are known as pre start-up safety reviews (PSSR) in the processing industry. 

So, what is a PSSC anyway? 

A PSSC is a final check before starting up equipment or systems that have been modified. It isn’t a replacement for commissioning, testing, or broader operational readiness programs. Instead, it’s about making sure that the right things have been checked, updated, and signed off — drawings, procedures, training, and risk controls included. 

Think of it like a pre-flight checklist. You might have flown this plane a hundred times, but if something’s been changed — however small — you still want to double-check everything before take-off. 

“But my change is only minor…” 

We hear this a lot. And it’s a fair point. 

Not every change requires a 10-page checklist and multiple review meetings. That’s where scalability comes in. A good PSSC process is tailored — meaning the level of review matches the risk and complexity of the change. Sometimes it’s just a few targeted questions. Other times, it’s a full, multi-discipline walkthrough. 

The key isn’t how big the checklist is — it’s whether it asks the right questions. 

What’s in it for you? 

Beyond the obvious safety benefits, a PSSC can: 

• Prevent costly delays during start-up due to overlooked items 

• Identify missing documentation or training needs before they become issues 

• Catch interface problems that weren’t obvious during the modification itself 

• Reduce the risk of equipment damage or operational failure 

• Avoid rework, downtime, or worst-case scenarios — safety incidents 

And let’s face it — no safety incident comes without a price tag, even when no one is hurt. Downtime, investigations, and reputational hits all cost money. In contrast, a targeted pre-start check is a small investment with a high return. 

Bottom line 

Pre start-up safety checks aren’t just for high-risk industries or massive changes. When tailored properly, they’re a simple, effective way to reduce risk and improve confidence before switching things back on. 

A well-designed PSSC process, built by people who understand the technical and operational context, can save your business time, money, and headaches. Done poorly — or skipped altogether — and you’re leaving things to chance. 

So before you hit “start,” pause for a moment and ask: Have we checked everything that matters? 

Chances are, it’s worth the effort with the key to success being: 

Right Process + Developed by the Right Experience = Maximum Value Attained