Study 6: Project Close-out /Post Start-up Review

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Study 6: Project Close-out /Post Start-up Review
CONTENTS
6.0 PURPOSE
6.0.1 Team
6.0.2 Timing
6.0.3 Preparation
6.0.4 Documentation
HAZARD STUDY 6: APPLICATION
6.1 METHOD
6.2 REVIEW OF HAZARD STUDY 6

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Study 6: Project Close-out /Post Start-up Review

  1. 1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com GBH Enterprises, Ltd. Process Safety Guide: GBHE-PSG-HST-070 Study 6: Project Close-out /Post Start-up Review Process Information Disclaimer Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the information for its own particular purpose. GBHE gives no warranty as to the fitness of this information for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed.
  2. 2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Process Safety Guide: Study 6: Project Close-out /Post Start-up Review CONTENTS 6.0 PURPOSE 6.0.1 Team 6.0.2 Timing 6.0.3 Preparation 6.0.4 Documentation HAZARD STUDY 6: APPLICATION 6.1 METHOD 6.2 REVIEW OF HAZARD STUDY 6
  3. 3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 6.0 PURPOSE The purpose of Hazard Study 6 is to provide an opportunity to: (a) Check that Hazard Studies 1 to 5 has been completed, and relevant documentation exists in the Project SSHE dossier (worksheet j); (b) Review early operation to ensure that it is consistent with the design intent with regard to safety, health and environmental issues, and that assumptions defined in earlier Hazard Studies are borne out in actual operation; (c) Identify and record operating and maintenance difficulties, and ensure feedback to the design engineering organization responsible for the project. This document should be used in conjunction with a process safety publication such as ’HAZOP: Guide to best practice’ (available from IChemE) or ‘Guidelines for Hazard Evaluation Procedures’ (available from CCPS). 6.0.1 Team The study team should include: (a) Commissioning Manager/Plant Manager; (b) Project Manager; (c) Hazard Study Leader/Safety Adviser, and where relevant: the Business Engineering Manager, Plant Engineer, Process Engineer, Environmental Specialist and Occupational Hygienist. 6.0.2 Timing Timing is most important for the successful completion of Hazard Study 6. Although it is important that this study is based on operating experience, a long delay can mean that the project and commissioning teams have been dispersed. The study should ideally take place not earlier than 3 months and not later than 6 months following the establishment of beneficial production.
  4. 4. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 6.0.3 Preparation The following information required for Hazard Study 6 should be in the SHE Dossier: (a) Reports from Hazard Studies 1 to 5. (b) Accidents and dangerous occurrence reports. (c) List and details of modifications. (d) Results of workplace monitoring (noise, vapors, dust). (e) Environmental monitoring and incidents. (f) Reports from safety inspections. Appropriate members of the project and commissioning teams should be asked to identify particular SHE-related issues which they think should be reviewed during Hazard Study 6. 6.0.4 Documentation A note should be added to the Project SSHE dossier (worksheet j) confirming that Hazard Study 6 took place and summarizing any actions identified and the responsibility for completion.
  5. 5. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com HAZARD STUDY 6: APPLICATION The following sections 6.1 and 6.2 describe how to conduct Hazard Study 6. 6.1 METHOD The points raised in part 1 and part 2 of the worksheet (worksheet t) should be systematically considered. Particular attention should be given to: (a) Review of operating experience (versus design conception). (b) Review of modifications, with significant hazard implications, made during the commissioning and start-up and check that the Piping and Instrument Diagrams (P&IDs) or Engineering Line Diagrams (ELDs), plant documentation and operating instructions have been updated. (c) Review of operation of the trip and alarm systems in terms of demand rates, spurious trips, trip defeats, interlock problems, and problems with testing.
  6. 6. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (d) Occupational health: review results of monitoring, exposure of operators, and frequency of leaks and spillages, are all in line with assumptions made for the Basis for Safe Operation. (e) Environment: review performance against consents, continuous discharges, and abnormal discharges. A record shall be kept in part 3 of the worksheet (worksheet t) of points raised that require further consideration, actions identified, and responsibilities allocated. 6.2 REVIEW OF HAZARD STUDY 6 At the completion of Hazard Study 6 the following key activities should have been completed: • Actions should have been assessed, reviewed and closed out. • Possible improvements, to be considered for future similar projects, should have been recorded.
  7. 7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

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