Pre-Startup Safety Review (PSSR) Checklist

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21 critical items still open - these are the highest-risk gaps.

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Design and construction

Construction and equipment confirmed to design specifications and P&IDsCRITICALAs-built P&IDs and equipment list updated and approvedCRITICALMaterials of construction verified against process chemistry and corrosion dataCRITICALPressure vessels, piping and relief devices inspected and pressure tested per designCRITICALRelief device sizing basis and discharge location reviewed and documentedInstrument loops checked, alarms and trip set points verifiedCRITICALElectrical area classification drawings match installed equipment

Procedures

Operating procedures written covering startup, normal, shutdown and emergency operationsCRITICALSafe operating limits and consequences of deviation documentedCRITICALMaintenance, lockout and isolation procedures in placeCRITICALEmergency shutdown and response procedures available and rehearsedCRITICALSafe work permit procedures cover hot work, confined space and line breakingProcedures reviewed by operators who will use them

Hazard analysis and change management

Process hazard analysis completed for new processes, with recommendations resolved or trackedCRITICALFor modified processes, management of change review completed and approvedCRITICALSafeguards identified in the PHA are installed and functionalCRITICALSafety information updated: hazards of materials, technology and equipment dataCRITICALIncompatible material and segregation review completed for storage and transferEnvironmental permits and discharge limits confirmed for the new or changed process

Training and readiness

Operators and maintenance staff trained on the new or changed proceduresCRITICALTraining records documented and availableCRITICALContractors informed of hazards and emergency actionsEmergency equipment, eyewash and showers tested and accessibleCRITICALRequired personal protective equipment available and fit-tested where neededSDS available for all materials in the process, and inventory records updated

Systems check and authorization

Utilities commissioned and verified, including nitrogen, cooling and instrument airCRITICALLeak and tightness test completed with water or inert gas before introducing hazardous materialCRITICALInterlocks and emergency shutdowns functionally testedCRITICALGas detection and fire protection systems operationalCRITICALPunch list items categorized, with critical items closedSigned authorization to start obtained from the plant manager and process safety representativeCRITICAL

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.

Startup readiness tracking

Ask for a short review of how PSSR, MOC and training records can be linked to your maintenance and quality systems.

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How to use the checklist

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.

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

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

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.

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

Frequently Asked Questions

When is a PSSR required?

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?

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?

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?

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.

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.

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