SAFETY DESIGN REVIEW - Minor MOC

Date:
MOC#, and Title:
SDR Team Members (please print first/last name - Process Engineer and RCC required)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

* Questions in all BOLD text require contacting PSM Leader to determine further study if yes answer.
* Questions answered YES must have an explanation/mitigation at the end of this form.
* DISCLAIMER SDR does not presume to mitigate all hazards and is a tool to address common risks. Additional tools include what-if, Hazop, or
NO.

PR-1
PR-2

PR-3
PR-4
PR-5
NO.

NO.
PR-6
PR-7
PR-8
PR-9
PR-10
PR-11
PR-12
PR-13
NO.

HF-1
HF-2
HF-3
HF-4

HF-5
HF-6
HF-7
HF-8
HF-9
HF-10
HF-11
NO.

NO.

GE-1
GE-2
GE-3
GE-4
GE-5
GE-6
GE-7
FS-1
NO.

RO-1
RO-2
RO-3
RO-4
RO-5
RO-6
RO-7
RO-9
RO-10
RO-11
NO.

PV-1
PV-2
PV-3
PV-4
PV-5
PV-6
PV-7
PV-8
PV-9
PV-10
PV-11
PV-12
PV-13
PV-14

PV-15
PV-16
PV-17
FE-1
FE-2
FE-3
FE-4
FE-5
FE-6
FE-7
FE-8
FE-9
FE-10
FE-11
NO.

EL-1
EL-2
EL-3
EL-4
EL-5
EL-6

NO.

IC-1
IC-2
IC-3
IC-4
IC-5
IC-6
IC-7
Item #

Attach additional pages if necessary.

SAFETY DESIGN REVIEW - Minor MOC

, and Title:
eam Members (please print first/last name - Process Engineer and RCC required)

ons in all BOLD text require contacting PSM Leader to determine further study if yes answer.
ons answered YES must have an explanation/mitigation at the end of this form.
LAIMER SDR does not presume to mitigate all hazards and is a tool to address common risks. Additional tools include what-if, Hazop, or similar advan
Process Engineering
Section NA?

Does the change create new, or change existing potential for high/low - pressure / temperature / flow / level in the system that equipment
ratings may be exceeded or hazard created? (Startup, shutdown, & normal operation)
Create new, or change chemical composition in the system such that vessel, pipe or equipment ratings are no longer adequate? (Consider chemical
compatibility of piping, gaskets, vessels, vessel internals, o-rings, etc)

Is there a change in product/process stream, a new product/process stream introduced, non-routine line-up change, or increased potential to create
reverse flow? (Consider the following: Creation of mix points, Change in concentration OR introduction when none present previously - H2S, Sulfur, O2, pH, NH3,
HCl, etc. Also consider chemical addition/ dose rate change)

Does the change require modification of - Key Process Reliability Parameters (KPRP), Standard Operating Conditions and Limits (SOCL) or Critical
Alarms?
Does the change create the potential for a phase change of process streams (liquid <-> vapor)?
Maintenance (RCC and/or Maintenance Supervisor)
Section NA?

Operations
Section NA?

Are there any process reactivity or catalyst changes?

Does the change adversely affect the process or equipment upstream or downstream of the change? (Consider process units, including utilities/or
tanks)
Has the change impacted stream composition affecting current sampling or testing methods?
Does the change affect procedure steps to loading/ unloading of products, chemicals, catalysts, or waste streams?
Does the change affect purge/steam out times/rates appropriate to the volume of equipment affected?
Could the process change impact any PSV design basis in the associated process? (PSV review required for rate changes above unit name plate)
Has process composition changed, affecting corrosion control variables in fixed equipment?
Does the system/change require punch listing?
Health & Safety
Section NA?

Does the change restrict the workspace and access around equipment for operations and maintenance? (Also consider temporary equipment;
scaffolding, temporary runs of hose, de-inventory piping, spill containment, etc)
Does the change restrict the space available for routine OR emergency access/egress?
Has lighting/visibility been affected, which would cause the need for lighting addition or modification?
Does the change restrict access to emergency isolation valves, controls, or emergency shutdown switches?

Does the change have potential to cause operator confusion and/or error due to operator/equipment interface?
Does the change restrict emergency response equipment access? (Fire engines, rescue equipment, etc)
Does this change impact existing, or require additional emergency response or detection systems? (Consider water deluge, LEL/H2S area monitors, etc)
Are there any equipment number or equipment service changes?
Does the change impact existing PPE requirements?
Does the change impact field or console operator response time? (Increased flow to vessel requires faster response time to a high level alarm OR
slower response to existing alarms?)
Is the change significant enough to require additional study (hazop) based on information gathered from the SDR?
Environmental
Section NA?

PSM
Section NA?

(Temporary MOC only) Does the change result in unsafe conditions while returning the equipment back to normal conditions (Consider process
and equipment issues; corrosion, contamination, carry-over, etc)?
(Temporary MOC only) When performing temporary repairs, does the repair require special consideration or alternative materials/methods until a
permanent repair may be completed?

Does the change introduce, modify or eliminate a defined confined space?

Does the change affect operating procedures (Normal, Startup, Shutdown, Emergency, or Temp ops), Process Manuals
or require Operator Training?
Does the change affect the sequence of steps for placing equipment in startup/shutdown mode of operations?
Does the change affect maintenance procedures or require craft training due to new or modified technology?
Has a design review for aduible/visual alarms been done?
Does the change introduce temporary trailers, shelters, occupied structures around process equipment or in processcovered units OR Introduce process equipment around non-process covered areas?
Pumps/Compressors/Turbines
Section NA?

Does the change create a hazard due to incompatibility of lubricants, buffer/seal fluids with process material?
Is there a change in fluid/gas properties (pressure, temperature, specific gravity, molecular weight)? Would a higher/lower density fluid affect the
discharge pressure to the point of causing a safety concern? (e.g., during an upset, start-up, or shutdown)

Does the change adversely impact equipment head pressure, temperature, rate, net positive suction head (NPSH)
ratings or violate minimum pump flow?
Does the change result in the potential for exceeding downstream equipment pressure ratings? (Caused by maximum
suction plus maximum discharge pressure)
Does the change create a potential for a double-pumping situation (series or parallel)?
Could process upsets exceed design temperature/pressure of the pump/compressor?
Does this change involve an impeller or speed change that will impact the HP requirements or max discharge pressure
of the pump or compressor?
Do changes impact pump/compressor support system(s) function OR require a change of the preventative maintenance
schedule or strategies? (lubricating systems, purge gas, seal flush, etc)
Does the change increase the potential for pump/compressor trip? Identify hazard & mitigation plan
Does the change modify the status of a pump to be or to no longer be considered critical?
Fixed & Fired Equipment (Heaters/Boilers)
Section NA?

Could pressure/temperature/hydraulic property changes create a new hazard based on piping specification? (Thermal
expansion or vaporization of trapped liquids, blocked pump discharge, pressure regulator failure, upstream cooler
bypassed, winter weather, cryogenic service)
Is the piping specification prone to failure due to changed process conditions, considering cyclical conditions? (Vibration,
temperature, pressure, auto-refrigeration from light-end flash off)
Could accumulated water or liquids freeze? (Low points, dead-leg/ intermittent service lines, pumps)
Could
operations
upsets
create,
or result
in (>400#
increased
corrosive
or corrosives
in valve
Will
thenormal
change
impact a or
high
pressure
letdown
valve
or >140#
on carry-over,
sample stations)?
Identifyaccumulate
the hazard...
seats, drain nipples, etc.?
Has the change created or increased the potential for metal dusting in a high temperature reducing service?
(e.g., hydrogen, methane, or CO)
Is the equipment vulnerable to environmental cracking? (Caustic in carbon steel, chlorides in stainless piping, non postweld heat treat carbon steel)
Does the change introduce risk of equipment failure due to high/low temperature? (creep/brittle fracture)
Does the change increase potential for plugging of piping or relief systems? (Rupture disk, heat tracing, steam purge, etc)
Do valves on relief valve inlet or outlet piping require new car seals or cause a need to remove car seals?
Does the change impact flare system tie-ins, hot tap, valve or lineup change, back pressure requirements, and
flare load considerations?
Does change impact relief system discharge points/areas that create a hazard to equipment/personnel? (Vents, relief
valves, rupture disks, flares, etc)
Does the change create a need for Inspection to identify appropriate inspection and testing methods?
Will the change require tie-ins or modifications to the Fire Water / Potable Water / Nitrogen / Plant Air or create hazards in the
event of a failure of one of these systems?

Will a change to equipment or process conditions create a need for, or affect emergency isolation valves?
Does the change impact equipment neutralization/chemical cleaning for maintenance or shutdown activities? (Consider
use of soda ash, acid wash, chemical hydro-cleaning products, caustic wash, pickling)
Does the change introduce water into a currently dry system or free water into a system where there previously was not?
Does the change impact explosion relief?
Does the change effect the burner control system not meeting applicable codes/ requirements for shutdown? Does the change effect
compliance with Boiler codes?

Does the change impact firebox purge system, heater startup/shutdown, or fire control?
Are key components for combustion air supply or draft impacted?
Does the change affect tube damage mechanisms? (corrosion, creep, sag, fouling, oxidation, chemistry, flame impingement)
Does change in design impact operational/maintenance access for observation ports for tubes, burners, or tube
supports? (burners, firing controls, air controls, tube supports, tubes, refractory)
Does the change impact fuel gas cleanliness (liquids, tip size, filtering, heat traced) or fuel gas isolation?
Does the change to fired equipment impact flare or relief protection for fuel gas or process materials?
Are there any refractory or internal structure changes? (Refractory specification/rating, drainage)
Are individual pass flow controls, indications, and alarms impacted?
Is inspection frequency or type of inspection mechanism impacted? (IR, thermal imaging camera)
ELECTRICAL
Section NA?

Will the change require an increased electrical load to be supplied from one of the following distribution systems? (Emergency Power, UPS, 600V,
115kV loads)

Will the change affect (add/delete/modify) any preventive maintenance strategies for electrical equipment?
Does the change require protection settings to be changed/ evaluated? (Motor (Multilin) protection settings, Distribution system relay/ breaker
settings or fuse changes)
Will the change require addition or deletion of critical heat trace circuits?

Will the change require changing of the electrical hazardous location in the process area and/or the instrumentation and electrical devi
Will the change require an electrical coordination and/or arc flash review to determine the arc flash category rating and appropriate PP

Instrumentation
Section NA?

Will the change require an addition, deletion, or modification of any kind to a Safety Instrumented System,
including change to MI testing requirements?
Is there new or modified control system configuration software involving logic or control loops, or require
changes of control system hardware?
Will the change require the addition, deletion, or modification to process or continuous emmission monitoring (CEM)
analyzers/ instruments?
require(add/delete/modify)
interlocks to be bypassed
(i.e. maintenance
startup/ shutdown, strategies
unit transition,for
etc)instrumentation
?
Will the change affect
preventive
or analytical
equipment?
Is there a change of materials for instrumentation (control valves, transmitters, float columns, etc.) or was there a
change to pipe specification with instrumentation attached?
Are there any process operating limits changes (Temp, Pressure, Composition, Flow), which affect instrumentation?
Item Description & Hazard Mitigation

Attach additional pages if necessary.

WO #
Department:
Department:
Department:
Department:
Department:
Department:
Department:
Department:
Department:
Department:

advanced analysis.
Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Yes

l devices in the area?

te PPE?

No

N/A

Yes

No

N/A

Pre Start up
Y/N

Target Date

Assigned to:

Date:
MOC#, and Title:

HR-01
HR-02
HR-03
HR-04
HR-06
HR-07
HR-09
HR-10
HR-11
HR-12
HR-13
HR-14
HR-15
HR-16
HR-17
HR-19
HR-20
HR-21
HR-24
HR-25

e:
C#, and Title:
* Questions answered NO must have an explanation/mitigation at the end of this form.

Assigned Enviance Actions

Assigned GoTrain Requirements (Insure Processing Form is filled out and submitted to GoTrain
Adminstrator)
Assigned Lynx Actions
Assigned Open projects
Environmental Training complete
H&S Training complete
HR Checklist completed.
Maintenance, MI, I&E training complete
Operator training complete
PDS Workflow update
Personal Office Equipment (Computer, cell phone, etc.) Issued
Personal Protective Equipment issued
Reliability Program Awareness
RR&Es written and reviewed with employee
Supervisor Training complete
Update Emergency Plan & Response contact list.
Update Facility Asbestos Manager
Update permit contacts, such as air and NPDES (If required, usually within 30 days)
Update Tier II emergency contact with fire department, LEPC, and SERC
Vehicle reassigned
Item Description & Hazard Mitigation

Yes

No

N/A

Pre Start
Target Date Assigned to:
Date: Y/N

MOC Training Decision

Purpose
This document provides guidance in deciding if MOC Training is required for Operations,
Maintenance or Contract employees and the level of training that should be performed (Self Study
/ Formal) for changes that are implemented through the MOC system.
Audience
Employees or contractors affected by a changed that are currently qualified in their job.
Training Required Self-Study or Formal Training?
Consider questions on both sides of the table below. Self-study or formal training may be
indicated if that side of the table clearly has more yes answers. Also, consider the different
audiences (operations, crafts, contractors, engineering, safety, etc.). While one audience may
require self-study, another may need more formal training.
Step 1: Is training required?
Answer questions below for Operations, Maintenance groups. A Yes answer to any of the
questions would indicate that training should be performed for appropriate group.
A.

Does change effect the way operations or B.

maintenance perform job task(s)?

Does change introduce new safety and

health hazards to Operations or
Maintenance? (Review SDR/PHA for
help)

C.

Does change effect Safe

Limits of Operations,
Critical Alarms?

Step 2: Determine level of training for each group

Only complete step two if it is determined that training is required. Review the table below for
each group that requires training.

Self-Study

Formal Training

Do employee job tasks and expected skill

levels stay about the same

Does MOC add a new task or skill

requirement?

Does change have very little impact on

existing job tasks?

Does change significantly change an

existing task?

Are job hazards NOT affected by this

change?

Does change introduce new hazards?

Do employee decisions and considerations

remain the same? No new knowledge is
needed?

Do affected employees have to make

different or more difficult decisions? Is
new knowledge needed?

Is this a simple change to existing

equipment?

Does this change introduce new

technology?

Do procedures and equipment operations

stay the same?

Does this change introduce new

procedures or operating expectations?

Can this change be learned by reading

about it?

Would employee performance benefit

from formal on-the-job training or
classroom discussion about this change?

Step 3: Actions for Training:

For self study the person assigned responsibility for training is required to provide a list of
affected departments and updated documents to the MOC Program Manager (i.e. SOP, ILT,
Rescue Plan, SOCL, PID update etc). This will be uploaded to the LMS system for all those who
require training.

For formal training the person assigned responsibility is required to arrange training and or
training materials. Once training is complete an Attendance Form must be filled out indicating
MOC #/Lynx Audit # and forwarded to the MOC Program Manager. This form can be found on
the Human Resources web page under training forms.