Study 5: Pre-commissioning Safety Review

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Study 5: Pre-commissioning Safety Review
CONTENTS
5.0 PURPOSE
5.0.1 Team
5.0.2 Timing
5.0.3 Preparation
5.0.4 Documentation
HAZARD STUDY 5: APPLICATION
5.1 TOUR OF THE PROJECT
5.2 REVIEW OF HAZARD STUDY 5

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Study 5: Pre-commissioning Safety 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-060 Study 5: Pre-commissioning Safety 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 5: Pre-commissioning Safety Review CONTENTS 5.0 PURPOSE 5.0.1 Team 5.0.2 Timing 5.0.3 Preparation 5.0.4 Documentation HAZARD STUDY 5: APPLICATION 5.1 TOUR OF THE PROJECT 5.2 REVIEW OF HAZARD STUDY 5
  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 5.0 PURPOSE The purpose of Hazard Study 5 is to: (a) Check that the detailed implementation of the project meets Regulatory and Company requirements; (b) Hand over the project. Key aspects include a review of: (1) Arrangements for the protection of employee health, covering the facilities provided and the arrangements for workplace monitoring; (2) Arrangements, including emergency systems, for employee safety; (3) Equipment and systems provided to protect the environment and for monitoring environmental performance. 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). 5.0.1 Team The Commissioning Manager is responsible for arranging the inspection(s) with the assistance of the following or their representatives: (a) Project Manager, (b) Safety Advisor, (c) Occupational Hygienist, (d) Site Environmental Advisor or Specialist.
  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 5.0.2 Timing The study takes the form of a pre-commissioning inspection of the plant or building and should be completed prior to the introduction of process materials or the commencement of operations, whichever is the sooner. However, the process may be started much earlier to avoid the risk which inevitably occurs around the time of mechanical completion. Regular plant tours during construction may assist in identifying problems at an early stage. Process materials include nitrogen, steam, air, water and chemicals (e.g. for chemical cleaning, pacifying). 5.0.3 Preparation The Commissioning Manager is responsible for arranging the inspection of the plant or building. 5.0.4 Documentation The Commissioning Manager should ensure that the Project SSHE dossier (worksheet j) has been updated. A list of any outstanding actions should be produced, together with the responsibilities for their completion, and added to the dossier. It may be helpful to identify which actions must be completed before the plant starts up. HAZARD STUDY 5: APPLICATION The following sections 5.1 and 5.2 describe how to conduct Hazard Study 5. 5.1 TOUR OF THE PROJECT A tour of the project should be carried out to check that it complies with regulatory, company and site requirements. A worksheet (worksheet s) is available which provides a guide to those areas that should be considered.
  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 A number of visits may be required at defined phases of the project. The guidance provided by the worksheet should be considered before each plant visit to select those factors appropriate for consideration in specific geographic areas. The safety adviser should be familiar with the list and should guide the other team members in a systematic inspection of relevant equipment and signs. First impressions of a plant are important because they can reflect the general standards of attitudes and management systems. This study serves to set the standards for future safety inspections and should therefore target for the highest practicable standards. Particular attention should be given to loading and off-loading installations, checking for good labeling and hazard warnings and for the control of vehicles to and from the installation. It is helpful to follow through the procedure for a vehicle and driver from the point of entering the facility through the loading or off-loading to the vehicle leaving the facility. 5.2 REVIEW OF HAZARD STUDY 5 At the completion of Hazard Study 5 the following key activities should have been completed: • Actions should have been assessed, reviewed and those considered to be essential closed out before start up. A strict timetable should be drawn up for the completion of the other actions.
  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

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