📘 Course Description:
This course provides in-depth training on the systematic control of changes to processes, equipment, people, and procedures through Management of Change (MOC) protocols, and how to verify safety before process startup using Pre-Startup Safety Review (PSSR).
Participants will learn how to identify, evaluate, document, authorize, and verify changes to prevent incidents caused by uncontrolled or poorly understood modifications. The course aligns with international best practices including OSHA PSM, API RP 750, and CCPS guidelines.
Through case studies, exercises, and templates, this course prepares professionals to implement robust MOC and PSSR programs within oil & gas, chemical, manufacturing, and power industries.
🎯 Learning Objectives:
-
Understand the purpose and principles of MOC and PSSR
-
Develop and implement effective MOC programs
-
Identify which changes require formal review
-
Conduct structured Pre-Startup Safety Reviews
-
Prevent startup-related incidents by verifying readiness
-
Ensure compliance with legal and industry standards
✅ Day 1: Foundations of MOC and PSSR
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Registration & Welcome |
| 09:00 – 10:30 | Introduction to Process Safety & Importance of Change Management |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Overview of MOC & PSSR Requirements (OSHA, CCPS, API) |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Types of Changes: Physical, Process, Organizational, Documentation |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | Common Incidents Caused by Poor Change Management (Case Studies) |
✅ Day 2: The MOC Process – Step-by-Step
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Initiating and Classifying a Change |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | MOC Evaluation: Technical, Safety, Environmental, and HR Aspects |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Approval, Documentation, and Authorization Procedures |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | Temporary vs Permanent Changes & MOC Workflow Tools |
✅ Day 3: Roles, Responsibilities, and Integration with PSM
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Roles of Engineering, Operations, Safety, and Management in MOC |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Training and Communication Requirements Before Change Implementation |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Integration with Process Safety Management (PSM) and Asset Integrity |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | MOC Audit and Performance Monitoring |
✅ Day 4: Pre-Startup Safety Review (PSSR)
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Purpose and Trigger Points for PSSR |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | PSSR Checklist Development and Field Verification |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Coordination Between MOC and PSSR Processes |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | PSSR Walkthrough Simulation and Common Gaps |
✅ Day 5: Case Studies, Exercises & Certification
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Interactive Case Study: MOC Implementation in a Refinery |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Group Exercise: PSSR for a New Compressor System |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Best Practices, Common Pitfalls, and Continuous Improvement |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | Final Q&A, Review, Exam, and Certificate Distribution |
📦 Course Materials:
-
MOC & PSSR flowcharts
-
Sample checklists & templates
-
Regulatory compliance guides
-
Group exercises & case study documentation
👥 Who Should Attend:
-
HSE and PSM professionals
-
Process engineers and supervisors
-
Maintenance & operations managers
-
Compliance officers
-
Project managers and plant inspectors
