Pre-Startup Safety Review Checklist
Use before introducing hazardous material or energy into new, modified, repaired, or restarted process equipment.
Scope and change control
☐
Installed scope matches approved design and MOC
Y / N / N/A
☐
Design deviations have documented technical approval
Y / N / N/A
☐
P&IDs, cause-and-effect charts, and equipment data are current
Y / N / N/A
☐
HAZOP, LOPA, relief, and project pre-start actions are closed
Y / N / N/A
☐
Temporary systems, overrides, and bypasses are listed and controlled
Y / N / N/A
Mechanical completion
☐
Equipment tags, materials, valve orientation, and flow direction verified
Y / N / N/A
☐
Pressure, leak, flushing, cleaning, and reinstatement records accepted
Y / N / N/A
☐
Flanges, blinds, vents, drains, caps, strainers, and temporary lines checked
Y / N / N/A
☐
Inspection and quality-control findings meet acceptance criteria
Y / N / N/A
☐
Construction work cannot affect containment, access, or startup
Y / N / N/A
Safeguards and systems
☐
Relief devices installed with an open discharge path and correct certification
Y / N / N/A
☐
Alarms, trips, interlocks, shutdown valves, and detectors function-tested
Y / N / N/A
☐
Firewater, deluge, communications, emergency power, and alarms available
Y / N / N/A
☐
Disabled safeguards and overrides removed or approved
Y / N / N/A
☐
Operating limits and shutdown conditions confirmed
Y / N / N/A
People, procedures, and permits
☐
Startup, shutdown, normal, abnormal, and emergency procedures approved
Y / N / N/A
☐
Operators and maintainers trained and understanding verified
Y / N / N/A
☐
Shift staffing and technical support adequate for startup
Y / N / N/A
☐
Construction permits and isolations closed or transferred under control
Y / N / N/A
☐
Simultaneous operations reviewed and conflicting work stopped
Y / N / N/A
Authorization
☐
Category A actions closed before startup
Y / N / N/A
☐
Deferred actions have risk controls, owners, approvals, and due dates
Y / N / N/A
☐
Final multidisciplinary field walkdown completed
Y / N / N/A
☐
Operations accepts the plant condition and documentation
Y / N / N/A
☐
Accountable manager gives formal go / no-go decision
Y / N / N/A
Use note: Adapt this resource to the site's hazards, legal duties, engineering standards, and management system. A checklist does not replace competent technical review.