# Pre-Startup Safety Review (PSSR) Checklist for Chemical Plants > Source: https://netray.co/tools/chemical-plant-pre-startup-safety-review-checklist > Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems. > Section: Free Tools ## Short answer A working PSSR checklist to confirm equipment, procedures, hazard analysis and training are ready before a new or modified process is started. ## Category ehs-workforce ## Industry Chemical Manufacturing ## Audience - Process safety engineer - Plant manager - EHS manager ## Tool **Kind:** checklist **Scoring Note:** A PSSR passes only when every critical item is closed or has an approved, tracked action with a named owner and due date before hazardous material is introduced. Non-critical open items should be listed with dates. **Groups:** #### Design and construction **Items:** **Text:** Construction and equipment confirmed to design specifications and P&IDs **Critical:** true **Text:** As-built P&IDs and equipment list updated and approved **Critical:** true **Text:** Materials of construction verified against process chemistry and corrosion data **Critical:** true **Text:** Pressure vessels, piping and relief devices inspected and pressure tested per design **Critical:** true Relief device sizing basis and discharge location reviewed and documented **Text:** Instrument loops checked, alarms and trip set points verified **Critical:** true Electrical area classification drawings match installed equipment #### Procedures **Items:** **Text:** Operating procedures written covering startup, normal, shutdown and emergency operations **Critical:** true **Text:** Safe operating limits and consequences of deviation documented **Critical:** true **Text:** Maintenance, lockout and isolation procedures in place **Critical:** true **Text:** Emergency shutdown and response procedures available and rehearsed **Critical:** true Safe work permit procedures cover hot work, confined space and line breaking Procedures reviewed by operators who will use them #### Hazard analysis and change management **Items:** **Text:** Process hazard analysis completed for new processes, with recommendations resolved or tracked **Critical:** true **Text:** For modified processes, management of change review completed and approved **Critical:** true **Text:** Safeguards identified in the PHA are installed and functional **Critical:** true **Text:** Safety information updated: hazards of materials, technology and equipment data **Critical:** true Incompatible material and segregation review completed for storage and transfer Environmental permits and discharge limits confirmed for the new or changed process #### Training and readiness **Items:** **Text:** Operators and maintenance staff trained on the new or changed procedures **Critical:** true **Text:** Training records documented and available **Critical:** true Contractors informed of hazards and emergency actions **Text:** Emergency equipment, eyewash and showers tested and accessible **Critical:** true Required personal protective equipment available and fit-tested where needed SDS available for all materials in the process, and inventory records updated #### Systems check and authorization **Items:** **Text:** Utilities commissioned and verified, including nitrogen, cooling and instrument air **Critical:** true **Text:** Leak and tightness test completed with water or inert gas before introducing hazardous material **Critical:** true **Text:** Interlocks and emergency shutdowns functionally tested **Critical:** true **Text:** Gas detection and fire protection systems operational **Critical:** true Punch list items categorized, with critical items closed **Text:** Signed authorization to start obtained from the plant manager and process safety representative **Critical:** true ## Content **Intro:** A pre-startup safety review is the last gate before hazardous chemicals enter a new or modified process. For processes covered by OSHA 29 CFR 1910.119, a PSSR is required for new facilities and for modified facilities when the change requires a change in process safety information. This checklist helps teams cover the ground consistently. **Sections:** #### How to use the checklist **Body:** Work through each group with the people who own the evidence: construction, procedures, hazard analysis, training and systems. Mark an item complete only when you have seen the document, test record or the installed equipment. Anything that cannot be closed should become a tracked action with an owner and a date. Critical items are the ones that should block startup if open. Export the completed list to PDF to keep with the project and change records. **Bullets:** - Attach the evidence reference next to each completed item - Walk the plant physically, do not rely on documents alone - Include an operator who was not involved in the project #### What the regulation expects **Body:** OSHA 1910.119(i) says the PSSR must confirm that construction and equipment meet design specifications, that safety, operating, maintenance and emergency procedures are in place and adequate, that a process hazard analysis has been performed and recommendations resolved for new facilities, that management of change requirements are met for modified facilities, and that training is complete. Other jurisdictions and company standards use similar logic, so the structure applies broadly even outside OSHA scope. #### Common mistakes **Body:** Frequent failures include treating the PSSR as paperwork signed after the fact, running it only after commissioning has already introduced hazardous materials, closing items verbally, and letting the project team review its own work. Keep the review independent enough to challenge, and make the authorization decision explicit. If the schedule is pressuring the review, that is itself a risk to record. **Bullets:** - Do not introduce process chemicals before the PSSR is approved - Include shift operators and maintenance in the review team - Keep the signed PSSR with the MOC package **Cta:** Netray can help connect your PSSR and management of change records to ERP assets, work orders and training records, so startup readiness is visible in one place. **Faq:** #### When is a PSSR required? **Answer:** Under OSHA 1910.119, a PSSR is required before startup for new facilities and for modified facilities where the modification requires a change in process safety information. Many companies apply it to a wider set of changes by policy. #### Who should sign the PSSR? **Answer:** The team usually includes operations, maintenance, engineering and process safety, with final authorization by plant management. Sign-off should come from people with the authority to stop the startup. #### How is a PSSR different from commissioning? **Answer:** Commissioning proves that equipment works. The PSSR confirms that the whole process is ready to operate safely with hazardous material, including procedures, training, hazard analysis and emergency readiness. Both are needed. #### Can startup proceed with open items? **Answer:** Only non-critical items with an approved, owned and dated action. Open critical items such as untested interlocks or missing procedures should stop startup until they are closed. ## Search terms pssr checklist, pre startup safety review checklist, osha 1910.119 pssr, pre-startup safety review template, chemical plant startup checklist, pssr after management of change, new process startup readiness --- Talk to an engineer: https://netray.co/contact?intent=erp_ai | Machine catalog: https://netray.co/agent/catalog.json