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.

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

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.

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.

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.

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

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