PSSR Checklist: How to Pass a Pre-Startup Safety Review (OSHA PSM 1910.119(i))

What a PSSR Actually Verifies

A Pre-Startup Safety Review (PSSR) under OSHA PSM 1910.119(i) is the formal field-verification that a new or significantly modified process is ready for safe startup. It is not a paperwork exercise — it is a physical walkdown that confirms construction matches design intent.

The Five Required PSSR Sections

1. Construction & equipment — built per specifications, materials of construction correct, instrumentation calibrated
2. Procedures — operating, maintenance, emergency, and safe-work procedures are in place and current
3. PHA recommendations — for new processes, PHA is complete and recommendations resolved or scheduled
4. MOC actions — for modified processes, every Management of Change action item is closed
5. Training — affected operators, maintenance, and contractors are trained and competent

P&ID Walkdown — What to Look For

• Every line, valve, instrument, and relief device on the as-built P&ID exists in the field
• Tag numbers match
• Bypasses, blinds, and temporary connections are documented or removed
• Vents and drains discharge to safe locations

Common PSSR Findings That Delay Startup

• Missing or expired calibration on safety-critical instruments
• Open MOC action items disguised as "punch list"
• Operating procedures not updated to reflect design changes
• Emergency isolation valves obstructed or hard to reach
• Inadequate training records for new equipment

Run Your Own PSSR

Download the Pre-Startup Safety Review Checklist template — a 3-page structured PSSR with field-verification items, sign-off matrix, and OSHA PSM 1910.119(i) cross-references. Free, OSHA-aligned, ready to adapt.

Software That Manages PSSR Workflow

If you run multiple turnarounds or capital projects per year, manual PSSR tracking breaks down. EHS platforms with MOC + PSSR modules (Tekmon, Intelex, Sphera, ProcessMAP) close the loop between PHA recommendations, MOC action items, and PSSR sign-off — see our QHSE software comparison for vetted picks.