Management of Change Pre-Startup Verification

Pre-startup safety review inspection for management of change, covering approvals, training, documentation, and field verification before startup.

Change Scope and Authorization

• Change description matches the approved MOC package
  Confirm the equipment, process, software, or procedural change being reviewed matches the approved management of change scope.
• Required approvals are complete and current
  Verify sign-off from required functions such as operations, maintenance, engineering, EHS, and management is complete before startup.
• Hazard review or risk assessment completed
  Confirm the change has been reviewed for process, mechanical, electrical, fire, and human-factor hazards as applicable.
• Temporary bypasses, overrides, or deviations are documented and approved
  Verify any temporary bypasses, interlock overrides, alarm suppressions, or deviations are formally approved with an expiration or removal plan.
• Startup authorization is issued
  Confirm the responsible authority has authorized startup after completion of the pre-startup review.

Training and Competency

• Affected operators have been trained on the new or changed process
  Confirm operators understand normal operation, startup, shutdown, abnormal conditions, and key hazards associated with the change.
• Maintenance personnel have been trained on new equipment or controls
  Verify maintenance staff received training on inspection, troubleshooting, isolation, and repair requirements for the modified system.
• Emergency response and abnormal condition procedures reviewed
  Confirm affected personnel know the response steps for leaks, alarms, trips, releases, fire, or other credible abnormal events.
• Training records are available and signed
  Verify training documentation is complete, dated, and signed or electronically acknowledged by the required personnel.
• Competency verification completed for critical tasks
  Confirm any required hands-on demonstration, qualification check, or competency assessment has been completed for critical operating tasks.

Documentation and Procedure Readiness

• Operating procedures updated to reflect the change
  Confirm startup, normal operation, shutdown, and emergency procedures are revised and available at point of use.
• P&IDs, schematics, or as-built drawings match the installed condition
  Verify engineering documents reflect the actual field installation, including valves, instruments, interlocks, and isolation points.
• Safety data sheets and hazard communication documents are available
  Confirm current SDSs, chemical labels, and hazard communication information are accessible for any new or changed materials.
• LOTO, permit, and isolation procedures are updated
  Verify lockout-tagout, confined space, hot work, line break, or other permit procedures reflect the modified equipment or process.
• Inspection and maintenance requirements are documented
  Confirm preventive maintenance, inspection intervals, calibration requirements, and spare parts needs are defined for the changed system.

Field Verification and Safeguards

• Installed equipment matches approved design and scope
  Verify the installed equipment, materials, and configuration match the approved change package and field markups.
• Guards, interlocks, and safety devices are installed and functional
  Confirm machine guards, emergency stops, interlocks, relief devices, alarms, and other safeguards are present and operational.
• Energy isolation points are identified and accessible
  Verify electrical, mechanical, hydraulic, pneumatic, thermal, and chemical isolation points are labeled and accessible for safe servicing.
• Housekeeping and access paths are clear
  Confirm access, egress, maintenance clearance, and emergency routes are unobstructed and free of trip or slip hazards.
• Fire protection and emergency equipment remain accessible
  Verify extinguishers, alarms, eyewash stations, showers, and emergency exits are accessible and not blocked by the change.

Startup Readiness and Closeout

• Open deficiencies are documented with owners and due dates
  Record any remaining non-conformances, assign corrective actions, and confirm they do not prevent safe startup.
• Outstanding punch list items are risk-assessed and approved
  Verify any remaining punch list items have been reviewed for startup risk and are formally accepted by the responsible authority.
• Startup decision recorded
  Document whether startup is approved, approved with restrictions, or not approved, along with the reason and approver.
• Inspector signature captured
  Capture the signature of the person completing the pre-startup verification.
• Review date and time recorded
  Record when the pre-startup safety review was completed.