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KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 1 of 27 Procedure for Project

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 1 of 27

Procedure for Project HSE Review (PHSER)

Document Number: KOC.GE.050

Document Author:

 

Document

Team Leader

Team Leader Safety

Coordinator:

Standards

Approved By:

KOC HSEMS Procedures Sub-committee

 

Authorized By:

KOC HSSE Implementation Committee

 

Original Issue

March 6, 2005

Document Control Tier:

Tier 3

Date:

Revision/Review

     

Date:

April 02, 2014

Next Review Date:

April 01, 2017

1.0 Purpose/Scope

The overall objective of the Project HSE Review (PHSER) process is to assure the Company that HSE-sensitive areas have been identified in a systematic way and that the Major projects, engineering and operational systems have been or will be developed to control / manage the identified risks. PHSERs are not “tools” in the way that Design Review, EIA, HAZOP, QRA, FTA, ETA, HAZAN, HAZID, etc. are, but rather a qualitative audit of the project’s HSE plans and actions. It does not suggest scope changes or alternatives but finds shortfalls and non-compliance out of the agreed & established Project’s HSE plan & actions. The process is meant to be “protective” and not “policing”; assurance and improvement are what is aimed at, not assessment and censure. PHSER recommendations are internal to the project, but the records must be kept to show that they have been acted on. PHSERs shall be conducted at all project stages in accordance with KOC procedures. To achieve optimized result of PHSER it is essential to maintain a ‘Hazard register’ of each project in the form of either electronically and/ or hard copy. The ‘Hazard register’ shall contain all HSE issues that have been raised/identified, from the initial stage of the project through commissioning.

PHSER & its role in HSE Management System

It gives an understanding of the methodologies employed and acts as basis for participation

within KOC.

Is a structured approach to examining the HSE risks It is composed of a number of

elements, which are tailored to suit the needs of the organization and/or project

An audit of project procedures and their implementation to ensure compliance with health, safety and environmental standards and legislations

Provides assurance to stakeholders that sensitive areas of HSE risk have been identified and appropriate procedures have been developed to manage these risks.

The scope of this procedure covers all KOC Directorates.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 2 of 27

2.0 Definitions

Project HSE Review (PHSER) Page 2 of 27 2.0 Definitions With reference to this procedure, a

With reference to this procedure, a state or condition or physical or chemical characteristic having the potential for causing damage to property and / or injury to people.

Risk: The term Risk in this procedure refers to HSE Risk. It is the likelihood of a hazard occurrence resulting in an undesirable consequence. Risks can be expressed in terms of impact of consequences and probability or frequency. For additional information, please refer KOC.SA.018, KOC.EV.001 and KOC.HE.018 procedures.

Project Stage:

One of the logical groupings of activities in which the PGS process is structured.

Hazard:

Project Phase: Projects are broken up into a number of project phases, each of which is a designated group of activities that normally result in deliverable or a milestone. Project Phases for the PGS were defined as follows:

Identification, Feasibility and Statement of Requirement, FEED, Project Validation, Execution, Commissioning, Operating and Monitor.

Project Gates:

A gate represents the point where a key management decision must be made before an opportunity/project can progress.

Project HSE Plan Gates: A series of check points in the development of Project HSE Plan from Identification Stage through to the Operate & Monitor Stage. The gates are moderated by Project HSE Plan Gatekeepers by means of Project HSE Plan Gate Check sheets.

Hazard Register: With respect to this procedure, Hazard Register is PHSER Action tracking register that contains all HSE issues that have been raised / identified, from Concept Selection Stage of project through commissioning phase. This is established by the Requesting Team during Concept Selection Stage and further updated during the Operations Stage. Controlling Team updates the Register during Project Definition and Execution Stages.

Requesting Team:

The Requesting Team is responsible for coordinating the activities and producing the deliverables for:

Stage 1.0 Identification

Stage 2.1 Concept Selection / Feasibility

Stage 2.2 Concept Selection / SOR

Stage 5.0 Operate & Monitor

KOC

For

Manual.

additional

information,

please

refer

Project

Gate

System

Controlling Team: The Controlling Team is responsible for coordinating the activities and producing the deliverables for:

Stage 3.1 Project Definition / FEED

Stage 3.2 Project Definition / Validation

Stage 4.0 Execution

For

Manual.

additional

information,

please

refer

KOC

Project

Gate

System

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 3 of 27

- Procedure for Project HSE Review (PHSER) Page 3 of 27  3.0 General Requirements KOC

3.0

General Requirements

KOC HSE MS Element HSE-03- 3

4.0

The PHSER Team conducts, within an agreed timetable and budget, a qualitative audit which avoids too much detail. Responsibility for planning, conducting, follow-up, delivery and action tracking of PHSER stages will be as per the following table:

Roles & Responsibilities

4.1 Roles & Responsibilities for PHSER

Table 1: Roles, Responsibilities and Timing of PHSERs

PHSER

Project Stage

Responsibility

Minimum Requirements

 

Concept Selection

Requesting Team

Conceptual definition by Requesting Team

# 1

Stage

PHSER action tracking system required

 

Project Definition

   

# 2

Stage (Basic Design HSE Review - Before Tendering Out)

Controlling Team

PHSER action tracking system to be updated

 

Project Execution

   

# 3

Stage Detailed Engineering & Design HSE Review

Controlling Team

PHSER action tracking system to be updated

 

Project Execution

 

PHSER action tracking system to be updated

# 4

Stage Construction HSE Review

Controlling Team

 

Project Execution

 

Hand-over from Controlling Team to Requesting Team once the project is completed and ready for introduction of hydrocarbons.

# 5

Stage Commissioning HSE Review

Controlling Team & Requesting Team

PHSER action tracking system to be updated.

 

Project Operate &

 

After 12 months following commissioning stage

# 6

Monitoring Stage HSE Review

Requesting Team

PHSER action tracking system to be updated

Notes:

1.

For Sub-surface PHSER, requesting team is Field Development (FD)

2.

Requesting team shall ensure resources for conducting PHSER are captured in the Project HSE Plan. Controlling Team is responsible for including the required contractual phrases regarding PHSER in the tender documents.

4.2 PHSER Team

a) The PHSER Chairman and Members should be completely independent of the Project under review but having relevant skills and competencies. In case the PHSER

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 4 of 27 Chairman is from

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 4 of 27

Chairman is from within KOC, then such person cannot belong to the same Asset/Directorate of the Team initiating the PHSER.

b) The PHSER Chairman must ensure that adequate information pertaining to the PHSER and Project under review are made available to the Team sufficiently in advance before commencement of the Review exercise so that the team members have thorough understanding of the Project development, are fully familiar with the current activities of the Project, are fully aware of relevant regulations and Company expectations and relevant previous studies. Requesting Team or Controlling Team, as the case maybe, should plan the PHSER process such that adequate time and means is available for the PHSER chairman to meet this requirement.

c) Typical review team includes:

A PHSER chairman, who is external to the project being reviewed but at the same time:

 

is from within KOC, OR

 

is a competent, third party approved by the Company as PHSER chairman.

 
 

The PHSER Chairman is appointed directly by the Team initiating the PHSER. If the PHSER chairman is from KOC, then such person shall be nominated & approved within the company directorate wise by respective Asset/Directorate HSE Team after evaluating his suitability & availability to perform such studies as requested.

The PHSER Chairman must have experience of the PHSER process and may specialize in this role. Full Time during PHSER study.

Minimum Qualification required for PHSER chairman is as follows:

 
 

o

Engineering Background (Chemical / Process Engineer) with 15 or more years of experience in Design & Engineering and/or Operation of Process Plants.

o

Must have participated as Full-Time Team member in at least 10 PHSERs.

o

Must have chaired at least five (5) PHSERs preferably for Oil & Gas projects in National / International Oil Companies.

A

secretary

who

should

prepare

the

report

with

the

findings

and

recommendations. Full Time during the PHSER study

 

Operations representative (independent of the project)Full Time during the PHSER study

Project Management representative (independent of the project) Full Time during the PHSER study

HSE representative(s).- Full Time during the PHSER study (From the same Asset / Directorate to which the Requesting Team and/or Controlling Team belongs depending on the phase of the Project). Representative from each discipline namely Health, Safety & Environment respectively shall be present during the review exercise.

Fire Team representative Full Time during the PHSER study. The Fire Team representative, where possible, shall preferably be from the Asset/Directorate to which the Requesting or Controlling Team belongs depending on the phase of the project.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 5 of 27 Following personnel may

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 5 of 27

Following personnel may be part of the Team on Full-Time basis as decided by PHSER Chairman:

· Maintenance representative (Mechanical / Electrical / Instrumentation)

· Inspection & Corrosion representative

The following personnel, including personnel from Contractor, will be involved in the PHSER process:

Technical safety specialist (as & when required)

Process engineer (as & when required)

Control / instrumentation / electrical engineer (as & when required)

Vessels, piping, rotating equipment engineer (as & when required)

Contractor & Sub contractor Project Manager, Construction Manager, QA/QC Manager, Planning Manager and Safety Manager (as & when required)

Other independent personnel may be required depending on the project risks. This would be decided by the PHSER Chairman.

Note: Composition of the Team will vary for each stage/phase of the Project. Team membership for each stage/phase will be decided by the PHSER Chairman for that respective stage. Requesting Team or Controlling Team, as the case maybe, should plan the PHSER process such that adequate time and means is available for the PHSER chairman to meet this requirement.

5.0 Project HSE Reviews

5.1 Projects, from an HSE point of view, are reviewed at various key Stages/Phases in their development, (in total there can be six (6) Project HSE Reviews for a Project, occurring at different stages/phases of the project). In some cases, PHSERs can be combined together where risks are acceptably low. The key objectives and scope of activities for each Project HSE Review exercise corresponding to particular stage/phase of the Project (please refer Table 1) are provided below:

5.1.1. PHSER #1: Concept Selection Stage HSE Review

Objectives

To confirm that significant HSE issues have been identified.

Note: Sometimes there may be a need for a PHSER review of Subsurface Developments prior to agreeing the projects concepts.

The scope of activities under PHSER #1 is provided in Appendix 1.

5.1.2. PHSER #2: Project Definition Stage (Basic Design HSE Review - Before Tendering Out)

Objectives

To confirm that all HSE concerns relating to the characteristics of the full lifecycle of the project, novel technology and the nature of the location have been identified.

To verify that all applicable regulations, standards, and relevant KOC expectations have been identified.

To confirm that an adequate Project Execution HSE plan has been established.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 6 of 27

To confirm that an adequate HSE risk management strategy has been established.

To confirm that a HAZOP strategy has been established.

The scope of activities under PHSER #2 is provided in Appendix 2.

of activities under PHSER #2 is provided in Appendix 2. 5.1.3. PHSER #3: Project Execution Stage

5.1.3. PHSER #3: Project Execution Stage Detailed Engineering & Design HSE Review

Objectives

To verify that HSE studies, including specialized reviews, are being satisfactorily addressed and followed-up.

To ensure that the HSE related aspects of the engineering designs meet or exceed regulatory requirements and that satisfactory project codes, standards have been identified and design philosophies have been established.

To confirm that Engineering Assurance processes are in place.

To confirm that Management of Change Procedures are in place.

To ensure that documentation requirements have been addressed.

To verify that a Resourcing and Training strategy is established.

To confirm that an HSE Management System including an HSE Plan is being implemented effectively and that pre-construction preparedness is adequate.

The scope of activities under PHSER #3 is shown in Appendix 3.

5.1.4. PHSER #4: Project Execution Stage Construction HSE Review

Objectives

To verify that project quality controls are sufficient to deliver plant integrity.

To confirm that the site change control procedure is being applied.

To confirm that construction workforce training and competence assessment arrangements are in place.

To verify that an HSE management system is in place and being implemented.

The scope of activities under PHSER #4 is shown in Appendix 4.

5.1.5. PHSER #5: Project Execution Stage Commissioning HSE Review (Prior to introduction of hazardous materials)

Objectives

To verify that pre-commissioning has been satisfactorily completed and the plant is ready for commissioning

To confirm that commissioning, maintenance and operational personnel are adequately trained, equipped and competent and that all necessary procedures are available. Fire Team also to be made aware of various hazards, available emergency systems and their handling.

To confirm that the Business Unit / Site has made adequate preparations for start-up.

To confirm that emergency response arrangements and procedures have been established.

To verify that deviations from design have been satisfactorily addressed and will not

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 7 of 27

compromise HSE performance.

Review (PHSER) Page 7 of 27 compromise HSE performance. The scope of activities under PHSER #5

The scope of activities under PHSER #5 is shown in Appendix 5.

5.1.6.

PHSER

#6:

Project

Commissioning)

Operate

&

Monitoring

Stage

HSE

Review

(~12

months

after

Objectives

To verify that HSE performance of the operating facility meets design intent.

To ensure that lessons learned from the execution of the project and early operation of the plant are captured and shared.

The scope of activities under PHSER #6 is shown in Appendix 6.

This HSE Review can be carried out in two stages. First one, within a month this is to identify bottlenecks with respect to HSE, which need immediate action. Second one, after 12 months this is to identify the problems that would arise after several cycles of operation

5.2 PHSER(s) are deliverables under a Project HSE Plan and are identified as checklist item in Appendices 2B-2G (KOC Project HSE Plan Gate Check sheets) of the procedure KOC.GE.048 (Procedure for Preparation of Project HSE Plan).

5.3 The PHSER team requests copies of key relevant documents for initial overview followed by clarification discussions. Site visits will be necessary for construction and operational phases. A typical list of documents to be reviewed (though not by any means comprehensive) is given below for reference. The documents to be reviewed will vary depending on the Stage/Phase of the Project:

HSE Plan & HSE Plan Gate Keeper Checklist

Reports of HSE Studies such as HAZID, HAZOP, QRA, EIA, SIL etc.

3D Model Reviews

Previous PHSER reports and status of action items

Design Change Procedures

Site Organograms

QA Audit Reports

Commissioning procedures

Emergency Response Plans

5.4 Each PHSER exercise will review the immediate previous PHSER report as well as status of recommendations of earlier PSHERs with the objective to verify status of implementation of these recommendations. Requesting Team or Controlling Team, as the case maybe, should ensure that all documents / drawings reviewed or mentioned in the immediate previous PHSER report are made available to the PHSER Team well before commencement of the review exercise (in line with requirement 4.2 b above) for verification of completion of action items.

5.5 Terms of Reference

Each PHSER will be undertaken against agreed Terms of Reference which will define the scope of work, time scale and team members. Typical contents of Terms of Reference are shown in Appendix 9.

5.6 PHSER Report

PHSER Team must use the worksheet format provided in Appendix 7 to note the findings

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 8 of 27 and recommendations with

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 8 of 27

and recommendations with responsibility and due date.

In case the findings indicate compliance, then corresponding space in the column ‘Recommendations’ must be marked as ‘Nil’.

After completion of the PHSER exercise, the PHSER Chairman must develop and submit a draft report to the Requesting Team/Controlling Team, as the case maybe, within Ten (10) working days. The report must be prepared in line with the content framework provided in Appendix 8. Upon receiving the report, the Requesting Team/Controlling Team, as the case maybe, must review and provide their comments to the PHSER Chairman within Ten (10) working days. Chairman shall resolve the comments and issue the final report within Ten (10) working days of receiving the comments.

6.0

Key Documents/Tools/References

 

KOC HSE Management System Guide December 2009

HSEMS Procedure GE.KOC.048 “Procedure for the preparation of Project HSE Plan(Revised June 21 st , 2011)

APPENDIX 1: PHSER #1: Concept Selection Stage HSE Review

APPENDIX 2: PHSER #2: Project Definition Stage (Basic Design HSE Review - Before Tendering Out)

APPENDIX 3: PHSER #3: Project Execution Stage Detailed Engineering & Design HSE

APPENDIX 4: PHSER #4: Project Execution Stage Construction HSE Review

APPENDIX 5: PHSER #5: Project Execution Stage Commissioning HSE Review (Prior to introduction of hazardous materials)

APPENDIX 6: PHSER #6: Project Operate & Monitoring Stage HSE Review (~12 months after Commissioning)

APPENDIX 7: PHSER Worksheet Template

APPENDIX 8: Typical PHSER Report Format

APPENDIX 9: Typical PHSER Terms of Reference

7.0

Abbreviations

EIA: Environmental Impact Assessment

ETA: Event Tree Analysis

FTA: Fault Tree Analysis

HAZAN: Hazard Analysis

HAZID: Hazard Identification

HAZOP: Hazards & Operability Study

PHSER: Project Health, Safety & Environment Review

QRA: Quantitative Risk Assessment

ALARP: As Low As Reasonably Practicable

CPP: Capital Project Proposal

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 9 of 27

- Procedure for Project HSE Review (PHSER) Page 9 of 27 8.0 HSE Records (Retention Period)

8.0 HSE Records (Retention Period)

All PHSER Reports

: Project completion & final acceptance period plus period for closure of all claims / rectification of warranty defects plus 5 years

Related Documents - tracking and close-out of PHSER

items,

action

correspondences

: Project completion & final acceptance period plus period for closure of all claims / rectification of warranty defects plus 5 years

Review and Revision Log

Review/

Revision Date

Review / Revision Details

03.12.2006

Rev-2: Internal review to effect PHSER roles & responsibility

15.09.2013

Clause 2.0 (old clause 3.0) Definitions: Added new definitions Clause 3.0 (old clause 4.0) General Requirements: Updated Clause 4.0 (old clause 5.0) Roles & Responsibilities: Updated Table 1 Introduced new sub-clause 4.2 ‘PHSER Team’. Typical Team composition was also updated. Clause 5.0 (old clause 6.0) Project HSE Reviews: Updated as given below New clauses from 5.1.1 to 5.1.6 Added typical list of documents to be reviewed

Review of immediate previous PHSER report Introduced new sub-clause 5.6 ‘PHSER Report’ Clause 6.0 (old clause 8.0) Key Documents/Tools/References: Updated New clause 7.0 ‘Abbreviations’ New clause 8.0 ‘HSE Records (Retention Period)’ Updated titles of Appendices Merged first part of Appendix 4 PHSER Stage 4: Construction Stage with Appendix 3: PHSER #3: Project Execution Stage Detailed Engineering & Design HSE Introduced new Appendix 7 ‘PHSER Worksheet Template’

02.04.2014

Clause 4.2.c: Updated qualification and experience requirement for PHSER

Chairman by deleting the mandatory requirement of past KOC Experience and requesting to chair at least five (5) PHSERs preferably for Oil & Gas projects in National / International Oil Companies.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 10 of 27

- Procedure for Project HSE Review (PHSER) Page 10 of 27 APPENDIX 1: PHSER #1: Concept

APPENDIX 1: PHSER #1: Concept Selection Stage HSE Review

Objective

Team Activity

1. To confirm that significant HSE issues have been identified.

1. Confirm that the HSE issues that could affect the viability of the potential project have been identified. HSE issues to consider should include:-

a. Hazardous properties of materials (feeds, products, intermediate streams and discharges)

b. Inherent safety

 

c. Processes and operations

d. Location in reference to access, distance from nearest Fire stations, topography for natural gradient etc. (Including sensitive receptors, land take etc.)

e. Contractors, partners, other stakeholders

f. Major incident potential (toxic / flammable inventories, high pressure / temperature operations, logistics)

g. Incident history of similar technology

h. Hazard analysis for similar technology

i. Identification of major emissions and discharges with treatment options

j. Regulatory and permitting concerns

k. Procedures to track, report and record HSE performance

l. Impact on Group HSE policies, e.g. minimum/zero flaring, climate change, biodiversity, water etc.

m. Lifecycle of the site, equipment and products

n. Health management

o. Construction risks

Supplemental Guidewords

1.1.a- MSDS Toxicity / Flammability Reactivity

1.1.b-

Substitution/Minimization Moderation / Simplification

1.1.c- Technology options Operating conditions Complexity

1.1.d- Sensitive receptors Land take Local community - buffer space Infrastructure & logistics

1.1.e- HSE policy alignment

1.1.i- Environmental impact To air, water, land

1.1.j- HSE Regulations Permit constraints 1.1.m- Decommissioning, remediation, restoration and exit Cradle to grave 1.1.n- Occupational health

Information Sources

Incident history of similar technology Hazard analysis for similar technology

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 11 of 27

- Procedure for Project HSE Review (PHSER) Page 11 of 27 APPENDIX 2: PHSER #2: Project

APPENDIX 2: PHSER #2: Project Definition Stage (Basic Design HSE Review - Before Tendering Out)

Objective

 

Team Activity

1. To confirm that all HSE concerns relating to the characteristics of the full lifecycle of the project, novel technology and the nature of the location have been identified

1.

Review the health, safety and environmental hazards inherent in the proposed development to ensure adequate

identification of those hazards that warrant special attention or further investigation. Confirm that acceptable solutions are available or are capable

of being developed within the timescale and organization of the proposed project. Topics considered typically include:

a) Properties of the process materials (MSDSs are required for all raw materials, products and intermediate streams)

b) Reactive chemicals mixing matrix

c) Processing conditions (normal, start-up, shutdown & excursion)

 

d) Process inventories, fire and explosion potential, stored energy, toxic release potential

e) Occupational health / health management

f) Impact on Group Policies, targets and strategies

g)

Project strategy for inherently safer design

h)

Transportation hazards / risks

2.

Review project plans to collect information on previous incidents and to address them in the design.

3.

Review the impact of the proposed development on existing facilities, and vice versa, both onsite and offsite. Review the interfaces between new and existing facilities.

4.

Review the proposed location to ensure that any characteristics of special HSE concern have been acknowledged, e.g. stakeholders, local population, local environment, sensitive receptors, geographical features, hydrology, biodiversity, meteorological conditions etc.

5.

Review draft construction philosophy including numbers in workforce, access to site, interactions with existing operations, significant hazards and environmental impact likely to be encountered during construction, including use of substances/materials hazardous to health and also the application of special Health, Safety and Environmental legislation.

6.

Review the expected emissions profile. The following will typically need to be considered over the full range of possible conditions, i.e. steady state, start-up, shutdown, emergency release, normal, maximum, end of run, etc.:-

a) Vents, oily wastes, wastewater, hazardous & non-hazardous solids & sludge

 

b) Flares

 

c) Noise, smell, visual impact

d) Point source & fugitive emissions

e)

Greenhouse gas and NOx emissions

f) Capabilities for offsite treatment and disposal

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 12 of 27

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 12 of 27
   

Objective

   

Team Activity

2.

To

verify

that

all

1.

Review the Project's list of approved specifications, Codes and Standards. Confirm that these are appropriate, taking

applicable

regulations,

into account current industry conventions and, where applicable, those in existence on associated existing facilities.

standards,

and

relevant

KOC

expectations

have

2. Review the strategy for assuring compliance with the KOC HSEMS Expectations.

been identified

 

3. Review the local and national regulatory requirements, and the project’s proposals for a “license to operate”.

3.

To

confirm

that

an

1. Review the Health, Safety and Environmental plan, and ensure that: -

adequate

HSE

plan

has

 

a) Adequate external, internal, specialized and peer reviews have been scheduled.

been established.

 

b) A plan has been developed for the conduct of PHSERs

 

c) The programme and intended organization for the procurement, execution and review of HSE studies, including

Health

Assessment and EIA etc. are in place.

d) Develop the Project HSE plan at the CPP stage and obtain HSE Group endorsement

e) The studies are scheduled to be completed in good time to ensure that actions can be incorporated into the design

and that resources are available in order to carry out the work. f) Contractor selection and procurement strategy aligned with KOC HSEMS expectations

2. Review the intentions for the tracking of actions arising from HSE studies.

3. Review the intended arrangements for the resourcing and training of the workforce for the development.

4.

To

confirm

that

an

1. Review the potential for significant HSE incidents. It is reasonable to expect initiation of : -

adequate HSE

risk

 

a) A Concept Safety Evaluation (CSE) if significant hazard potential is identified.

management strategy has

b) An Environmental Impact Assessment (EIA) if significant environmental impact potential is identified.

been established.

 

(In both instances the potential will generally be regarded as ‘significant’ if lasting impact beyond the plot boundary is possible. The review should include consideration of the potential for a materials receipt and dispatch incident.)

 

2. Review the proposed criteria for tolerable risk and the means by which the project intends to evaluate the design against these criteria and demonstrate that risk will be minimized (ALARP). Review if a QRA will be needed. Does project significantly change the site risk profile?

3. Review the design principles for safety and environmental risk control and mitigation features, including :-

 

a) process containment

b) unit separation / layout

c) Protective systems (i.e. relief systems, fire protection, etc.)

d) isolation philosophy

e) protection of personnel

f) emergency service provisions/emergency response plan

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 13 of 27

- Procedure for Project HSE Review (PHSER) Page 13 of 27   Objective   Team Activity
 

Objective

 

Team Activity

 

4. Review HSE risk management strategy for outsourced facilities

5.

To

confirm

that

a

1. Review proposals for ensuring that the scope of the HAZOP study includes all aspects of the development, including vendor packages, with a significant hazard potential.

HAZOP strategy has been

established.

 

2. Review the proposed timing of the HAZOP study, resourcing, and in particular arrangements for incorporating findings in the specifications for early-order items.

Supplemental Guidewords

   

1.2. Incident prevention Similar facilities feedback

1.6

Environmental impact

4.1.a Occupied buildings

Wastewater run-off, containment, processing and re-use Emissions during abnormal operations Noise (local and community) Biodiversity Lifecycle assessment

4.3

Siting, spacing,

1.4

Flooding Wind loads Earthquakes Ice / snow load Sand storm

Extreme temperature

population distribution, public receptors (schools, hospitals etc.)

5.1

HAZOP Methodology

1.5

Special construction

Water management

 

techniques Occupational Health and Safety during construction Modification to live plant Adjacent activities Timing of phases Accessibility

2.3

Local labor restrictions

Information Sources

Appraise Stage PHSER report and Project responses Description of the proposed development including the processing route and Statement of Requirements. Studies concluded regarding choice of plant, process and location and Concept Safety Evaluations. Process flow diagrams, site plans etc. Material and energy balance Process description Inventories of hazardous materials Proposed Standards and Recommended Practices for Engineering. Acceptability criteria for quantified risk assessment. Substances/Materials used, MSDS, properties. Information on similar projects. Past PHSER reports of the same stage on similar developments. General statement of policy and requirements on Occupational Health and Safety during construction. Environmental Impact Assessment or equivalent, environmental strategy, protected area mapping Client's HSE policy for the proposed development. HSE compliance standards. Energy efficiency studies on the selected processes. HAZOP Strategy Risk Management plan Environmental emissions/waste profile Lifecycle assessment Health Map/Health programme Biodiversity action plan

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 14 of 27

- Procedure for Project HSE Review (PHSER) Page 14 of 27 APPENDIX 3: PHSER #3: Project

APPENDIX 3: PHSER #3: Project Execution Stage Detailed Engineering & Design HSE

Objective

 

Team Activity

 

1. To verify that HSE

1. Confirm that recommendations arising from previous PHSER stages and other HSE studies, including HAZOP, CSE, QRA, EIA, and Health Map are being addressed.

 

studies,

including

specialized reviews, are being satisfactorily addressed and followed-up

2. Confirm that a system is in place to register and track the close out of HSE actions.

 

3. Check

that

the

HAZOP

study

has

been

undertaken

on

all

systems,

including

vendor

packages,

in

a

satisfactory manner

and

that recommendations are being resolved in a timely manner and that closure is properly

documented.

 
 

4. Review the justifications for HAZOP recommendations that have been rejected.

 

5. Review whether there have been any changes in project scope and confirm that the relevant HSE studies have been updated.

 

6. Review any Project studies on hazard identification. Confirm that all areas of the new facilities and interactions with adjacent facilities have been considered. This should include hazards that could arise during normal, start-up, shutdown, maintenance, transient and emergency operations and those associated with construction.

7. Confirm that solutions to the identified hazards are available and incorporated or are capable of being developed within the timescale and organization of the proposed project

 

8. Confirm that appropriate Specialized Reviews have taken place and results incorporated, e.g. Instrumentation and Control, Logistics, Human Factors, Ergonomics and Alarm Management

 

9. Confirm that reviews targeted to improve HSE performance, such as ergonomics, design for safe construction, and 3-D model reviews of layouts for personnel hazards, accessibilities, and locations of safety equipment have been conducted and results have been incorporated.

10. Confirm that a review is planned to provide HSE assurance of project site preparedness prior to mobilization.

 

11. Confirm that Occupational Health studies are being addressed.

 

2. To ensure that the HSE related aspects of the engineering designs meet or exceed regulatory requirements and that satisfactory project codes, standards have been identified and design philosophies have been established.

1. Review the Project's list of specifications, codes and standards to confirm that these are appropriate and, where applicable, compatible with those on the existing facilities. Verify that the design is being developed in compliance with these specifications, codes and standards.

2. Confirm that the basis of detailed design acknowledges both established good practice and "lessons learned" in the application of the technology concerned.

 

3. Confirm that the bases of detailed design for all of the individual systems which are likely to influence HSE performance satisfy regulatory and client requirements.

4. Confirm that the design acknowledges all the HSE features of both the technology and the location, which demand special attention. Review in particular any novel features, which may affect HSE performance, and any special considerations, of vendor packages.

 

5. Review the proposed means of maintaining operations within the design envelope, and identify and assess any special features.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 15 of 27

- Procedure for Project HSE Review (PHSER) Page 15 of 27 Objective Team Activity   6.

Objective

Team Activity

 

6. Confirm that HP to LP interfaces and primary pressure protection accomplished completely or partially by instrumentation have been identified and appropriately considered in the design.

7. Review the design philosophies relevant to HSE performance. These will typically include over-pressure relief/over- temperature protection, vibration monitoring, isolation, control and shutdown systems, safety instrumented systems, fire and gas detection, fire protection, emissions control, pollution prevention, noise abatement etc.

8. Review the design basis for the flare system including layout, materials of construction, flame front generator, and instrumentation used to reduce flare loads.

9. Confirm that Safety Integrity Levels (SIL) for Safety Instrumented Systems has been determined using an appropriate method with suitable specialist input. Confirm that the calculated SILs have been taken into account in proposed hardware configurations, for example, is a highly reliable logic solver (e.g. Triconex) required? Confirm that safety instrumented systems have been designed to provide the required Safety Integrity Level (SIL) and testing frequencies for components have been determined.

10. Review HSE critical equipment identification.

11. Review the Project's HSE management system to verify compliance with “KOC HSEMS”.

12. Review progress on the proposed operating license acquisition strategy.

13. Review HSE design philosophy for all occupied buildings and confirm that the designs will provide adequate

protection for personnel, that it meets Group criteria for acceptable risk, and complies with all regulations and location building codes. Confirm that a thorough analysis of blast overpressure scenarios has been performed.

Ensure that the methods of installation and construction to be adopted are being addressed in the development of the design, including an assessment of risks.

14.

3. To confirm that Engineering Assurance processes are in place.

1. Confirm that the levels of technical authority for the design are clearly established in Project procedures, understood at all levels and are being applied.

2. Review the management of interfaces that exist between multiple designers, vendors, multiple sites etc.

 

3. Confirm that the competence of personnel key to technical integrity has been verified.

4. Confirm that a system exists whereby when the design contractor or a vendor departs from the specified standards etc. that this departure is reviewed and approved by the Project and included in the Project's design dossier.

5. Review the process for inter-discipline checks of the design.

6. Confirm that criteria for selection of contractors, subcontractors, major vendors, and outsourced facilities include HSE considerations and these criteria have been applied and are being maintained, including an assessment of the competence of contractors whose activities are critical to technical integrity.

7. Confirm that there is accountability for identification, verification and compliance with statutory requirements and obtaining the required consents to operate the facilities. Review progress of submissions.

8. Review the QA/QC plan for the project and confirm all activities are subject to system and compliance audits and that findings are followed up and closed out. Sub-contractor and vendor audit trails should be in place for all design, procurement and fabrication activities.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 16 of 27

- Procedure for Project HSE Review (PHSER) Page 16 of 27   Objective Team Activity 4.
 

Objective

Team Activity

4.

To confirm that

1. Confirm that the change control procedures (MOC) apply to all changes that might affect the HSE performance of the intended development or the HAZOP integrity.

2. Verify that change control procedures are adequate by checking project documents. E.g. P&IDs and Cause and Effects post HAZOP.

Management of Change Procedures are in place

3. Verify that changes to P&IDs, Cause and Effect Diagrams, Hazardous Area Classification Drawings etc. Post HAZOP are properly controlled and authorized.

4. Review the process for inter-discipline checks of design changes.

5. Review whether there have been any changes in scope and confirm that the relevant HSE studies have been updated.

5.

To ensure that

1. Confirm that adequate provision has been made for the supply of HSE related documentation required by host site operating and maintenance systems.

2. Check proposals for data management and transfer into site systems, e.g. maintenance management, engineering records.

documentation requirements have been addressed.

3. Confirm that engineering contractor will obtain from vendors recommended mechanical integrity procedures for all equipment.

4. Confirm the documentation requirements for the relief and flare systems and that relief/flare system calculations have been updated based on isometrics and vendor data. Review compilation of a Register of Safety-Related Devices.

5. Review the procedure for control and issue of latest design documentation.

6. Confirm arrangements for providing the as-built documentation prior to start-up.

6.

To verify that a

1. Confirm that the outline operating and training strategies are compatible with HSE related design assumptions. This should include development of operating, maintenance and HSE procedures; manning levels; training provisions (e.g. simulator); planned maintenance frequency; inspection frequencies; and emergency response capability.

Resourcing and Training strategy is established.

7.

To confirm that an HSE

1. Review the Project's HSE Plan and confirm compliance with it.

Management System including an HSE Plan is

2. Check that a strategy is in place for the integration of the new facilities in the host site HSE procedures and plans.

3. Confirm that adequate arrangements are being made for the collation and transfer of all information required to enable safe and efficient future operation of the facilities.

being

implemented

effectively and that pre- construction preparedness is adequate.

4. Review progress on the development of operating, maintenance and HSE procedures.

5. Confirm that the Project's HSE management system is in p lace and being implemented.

6. Confirm that a Construction Safety Plan has been developed and that a pre-site mobilization review has been conducted and HSE assurance provided.

 

7. Review proposals for training and site induction of personnel.

8. Review proposals for inspection, testing, pre-commissioning, and pre-start-up safety review to confirm that they provide for adequate HSE integrity.

9. Confirm that P&IDs and isometrics are sufficiently completed to commence construction.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 17 of 27

- Procedure for Project HSE Review (PHSER) Page 17 of 27 Supplemental Guidewords   1.1 Action

Supplemental Guidewords

 

1.1

Action closure

2.8

Relief scenarios

7.7.

Lower tier

documentation

Methodology

subcontractors

1.5

Adjacent Hazardous

2 phase relief

7.9.

Integrity (vessels,

Plant Impact on community of construction & operation

2.11

Health Management

structures, pipe work) Reliability (machinery, shutdown system, power

2.13

Building Access-Egress Provisions for shelter in place

Separation distance

1.7

DCS / Interlocks / Alarm

supplies)

Management

Commissioning

2.2

Previous incidents -

Gas detection systems

prevention

2.14

Constructability

2.4

Innovation

Machinery Mechanical Handling (Cranes, Hoists, Fork Lift) Buried & Overhead Services

3.6

Procurement strategy

Exclusion of the Public, security Perimeter Fencing Environmental: - Temperature, Barometric Pressure, Freezing Fog, Chill Effects, Prevailing Wind, Tides, Wave Height, Rainfall, Flooding Winterization (lagging, tracing, walkways)

HSE

Considerations

3.7

Special regulations

Emissions Waste generated/disposal

2.5

operating and safe limits

Margins between

2.7 Hazardous chemicals Radioactive materials Hazardous inventories Leakage Explosion/Fire Waste management Discharges /Effluents, Vents, Flares, Drains, Solid waste disposal, greenhouse gas,

4.1

HSE design transfer Change documentation Change authorization Change implementation

Changing contractors,

5.1

Process safety

information development and transfer

6.1

Mechanical integrity

Support

Information Sources

Project organization and schedule Status reports from HSE study recommendations Business Statement of Requirements P&IDs, PFDs, Process description Location and layout of facilities, plot plans Preliminary hazardous area classification Technical Specifications (process design package) Individual study reports, e.g. surge analysis, reliability analysis, surveys (soil, flooding, etc.), mass and energy balances, properties of process substances, MSDS, corrosion / environmental aspects, occupational health aspects, QRA Identification of package units and vendor provided systems Operation and Maintenance Philosophy, staffing and training plans, procedures development strategy, mechanical integrity strategy, emergency response strategy Safe, design, and operating envelopes HSE philosophy, HSE plan, including risk management Environmental Impact Assessment, expected envir. profiles Permit acquisition plan and status Relief philosophy, scenarios and design strategy Control philosophy, Isolation strategy Emergency shutdown strategy Fire and Gas detection strategy, Fire Protection strategy Applications of safety systems and safety instrumented systems Concept Safety Evaluation Outline Register of Protective Devices Project management of change procedures List of changes and supporting documentation HAZOP report(s) and other hazard and risk studies Occupied buildings HSE design philosophy List of variances from specifications Contractor/subcontractor/vendor selection criteria Project documentation strategy Biodiversity action plan, Lifecycle assessment Monitoring studies and baseline surveys FEED PHSER report and recommendation resolutions HAZOP study reports and recommendation resolutions

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 18 of 27

- Procedure for Project HSE Review (PHSER) Page 18 of 27 NOx Noise (local and community)

NOx Noise (local and community) Soil Conditions Biodiversity action plans Utilities (Steam, Air, Nitrogen, Water, Fuels, Electricity) Philosophies (Operation, Maintenance, Safety, Relief, Venting, Environmental) Emergency alarm & protection systems Public notification systems Fire protection Ignition source control/location Hazardous area classifications (electrical equipment)

7.1.

Abandonment

Detailed layout drawings incl. P&ID, flow sheets and single line electrical drawings Area classification drawings Engineering Specifications Equipment specifications Package specifications 3-D model (if available) QA manual (Designers - KOC or Contractor) Document/Certification Control Dossier Quality Audit reports on Design Office Actions arising from EIA Register of Safety Related Devices (or equivalent) Deviations Register Occupational Construction Safety Plan QRA Reports & Environmental Impact Assessments Change lists and associated documentation Project HSE Plan, construction HSE Plan, pre -commissioning plan, subcontracting strategy

7.4.

Abnormalities (starting

up, shutting down, reduced flow, emergency shutdowns).

7.6.

Construction HSE risks

Adjacent live plant Phasing of work Worker camp set up Fire prevention Flammability/ toxicity of construction materials Fabrication Demolition safety Excavations/tunnels Modular construction Design of major lifts Steel erection methodology Lighting

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 19 of 27

- Procedure for Project HSE Review (PHSER) Page 19 of 27 APPENDIX 4: PHSER #4: Project

APPENDIX 4: PHSER #4: Project Execution Stage Construction HSE Review

 

Objective

 

Team Activity

1.

To

verify

that

project

1. Review the Quality plans and Audit programmes for the Project and contractors and confirm that these are being implemented.

quality

controls

are

sufficient

to

deliver

plant

2. Review the Project internal controls and procedures relating to inspection, testing and material control. Confirm that they provide assurance that construction, fabrication and materials management activities are being carried out in accordance with the design.

3. Confirm that the design intent has been maintained during the fabrication, construction and installation phases.

integrity.

 
 

4. Review arrangements for punch listing and pre commissioning

 

1. Establish that a change control procedure (MOC) is in place to manage deviations from codes, standards and specifications and all changes affecting P&IDS in project and contractor / sub -contractor organizations.

To confirm that the site

change control procedure is being applied.

2.

2. Review Project document control procedures.

3. Check that the levels of technical authority for authorizing changes are established, understood and are being applied.

4. Review the availability of up-to-date design information at the “workface” and the systems in place to ensure that up to date information is available at all times.

3.

To

confirm

that

1. Confirm that a site HSE Induction process, including hazard identification training, has been established and applies to all project related personnel, including lower tier subcontractors.

construction

workforce

training

and

competence

2. Confirm that adequate competence assurance programmes are in place and are being implemented for all trades.

assessment arrangements are in place.

 

1. Confirm that recommendations from previous HSE Reviews for Projects and other HSE studies are being addressed and that actions are being implemented.

2. Confirm adequate emergency and contingency plans are prepared for the construction period and integrated with existing site emergency Plans.

3. Confirm that a Safe System of Work is in place, including topics such as Permit to Work, isolation of process and

4.

To verify that

an HSE

electrical equipment, Confined space entry and task based risk analysis.

management system is in

4. Confirm that a programme of site inspections and HSE meetings (e.g. toolbox talks, safety representatives meetings, workforce / Management meetings) is in place and is being implemented effectively.

place

and

being

implemented.

 

5. Confirm that the requirements for site specific procedures such as Combined Operations, Simultaneous Operations have been assessed and Implemented as necessary.

 

6. Check that a Project procedure for assessing Contractor HSE Management Systems is being implemented.

7. Confirm that HSE management systems are effectively implemented throughout the construction organization, including lower tier Subcontractors.

8. Check that a system exists for the development and authorization of method statements for tasks with identified

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 20 of 27

- Procedure for Project HSE Review (PHSER) Page 20 of 27   Objective   Team Activity
 

Objective

 

Team Activity

 

hazards and performance of JSAs (job safety assessment). Confirm that the hazards identified by the JSAs are being effectively managed. 9. Confirm adequate site security and medical arrangements

Review procedures for ensuring that all appropriate construction regulations have been identified and are being applied.

10.

11.

Review procedures for tracking and reporting HSE performance. Confirm that appropriate HSE monitoring

programmes are in place, and are driving performance improvement. Review incident investigations and lessons

learned.

12.

Review progress on regulatory submissions with respect to target start -up date.

Review equipment flushing, cleaning, steam-blowing, drying etc. procedures include HSE considerations, e.g. disposal of fluids, noise etc.

13.

 

Supplemental Guidewords

   

Information Sources

1.2

Variances from

3.2

Health and safety

4.4 Housekeeping Fire protection standards Cranes and lifting gear

Pre-construction Stage PHSER report and Project responses Design changes HAZOP recommendation status and closure documentation Certification/Inspection documentation procedures Site co-ordination procedures Site & HSE organization charts (KOC/Contractor) QA audit reports on Vendors, Contractor, KOC QA Programme and bar chart of construction activities Overview of responsibilities and functions of KOC, Contractor, Subcontractor, Agencies, other third party involvement, suppliers, stockists. Additional reports, surveys Planning permission Local statutory regulations Impact of EIA on construction Construction site Safety Procedures Occupational Construction Safety Plan Occupational Construction Safety Audit report List of variances from design specifications Pre-commissioning plans Emergency plans P&Ids Punch lists Pre-Startup safety review checklist and plan Health Management plan

specifications Certification Positive materials

identification

training

4.1

Behavioral safety

 

programme

4.5

Work over live plant

4.2 Community relations

Site radiography work on an

1.3

(Design) Audits and

operating facility

follow-up

4.3 Safe access/egress

Staging areas vs. site hazards

4.6

Subcontractor pre -

1.4

Pre-commissioning

qualification and control

hazards Liaison (Pre Start -Up Stage) Pre-Startup safety review planning/strategy

Fall protection Excavation safety Electrical safety Demolition Scaffolding standards

4.9

Worker camp conditions

4.10 Environmental management

3.1

Substances hazardous

 

to health Industrial hygiene Personal protective equipment Multi-language workforce Multi-cultural workforce Experience of workforce

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 21 of 27

- Procedure for Project HSE Review (PHSER) Page 21 of 27 APPENDIX 5: PHSER #5: Project

APPENDIX 5: PHSER #5: Project Execution Stage Commissioning HSE Review (Prior to introduction of hazardous materials)

 

Objective

 

Team Activity

1.

To

verify

that

pre-

1. Confirm that any recommendations arising from all previous Project HSE Reviews and other HSE studies have been addressed and actions implemented and closure documented.

commissioning

has

been

satisfactorily

completed

2. Confirm that the necessary approvals have been obtained for license to operate.

and the

plant is

ready for

3. Review the project commissioning plan.

commissioning

4. Establish that a hand -over system is in place that provides assurance and documented evidence that the plant has been built and pre-commissioned in accordance with the design.

 

5. Review the utility, protective HSE devices and support systems that will be fully commissioned, including testing where appropriate, before the plant starts up.

6. Confirm that the Project's Register of Safety Related Devices (or equivalent) has been completed and handed over to the operator.

7. Confirm that a system for punch listing is in place and that all high priority items will be completed before commissioning starts.

8. Review the delivery of as -built documentation and Process Safety Information and its subsequent control by the site.

9. Ensure that adequate spares are available for commissioning and the initial operation of the plant.

10. Ensure list of chemicals and their quantity is made available along with MSDS, safe system of disposal and antidotes for treatment.

2. To confirm that commissioning, maintenance and operational personnel are adequately trained, equipped and competent and that all necessary procedures are available. Fire Team also to be made aware of various hazards, available emergency systems and their handling

1. Confirm that adequate systems and procedures, both for commissioning and subsequent operations have been prepared for start up, shutdown, normal operation, emergency shutdown, maintenance and testing of the facilities. This includes procedures for all phases of operation, including temporary operations.

2. Confirm that safe work practice procedures have been developed and the workforce fully trained.

3. Review the level of resources, skills and training that has been provided to commissioning personnel, including HSE induction and training specific to the site. Confirm through interviews that the workforce has understanding of operating and safety procedures and has the competencies and skills for safe start -up and operation.

4. Review facility’s analysis of emergency procedures that assures facility has adequate staffing of operators to bring unit to a safe state during Emergencies.

5. Review the arrangements in place to ensure that all personnel involved with commissioning activities are competent to do so and that the operator has similar standards in place to ensure long term safe operation of the plant.

6. Confirm that the necessary vendor support for all mechanical, instrument, electrical and control equipment will be available.

 

7. Confirm that the facility’s process safety management program has been fully developed implemented, and personnel are trained and, where appropriate, integrated into existing site programs. This includes all “KOC HSEMS” elements, including management of change procedures.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 22 of 27

- Procedure for Project HSE Review (PHSER) Page 22 of 27   Objective     Team
 

Objective

   

Team Activity

3.

To confirm that the

1. Review the Operator's HSE Management System to ensure that an update has been or will be carried out to include the new facilities. Any changes introduced by the project should not affect the sites ability to meet the expectations of “KOC HSEMS”.

2. Review handover of HSE management responsibilities to site (e.g. MOC, security, contractor oversight, permit systems etc.)

Business Unit / Site has made adequate preparations for start -up

3. Review the Operator's Maintenance Management System, ensuring that all necessary maintenance data has been input and the system has been tested.

4. Confirm the availability of procedures to carry out the periodic testing of high integrity protection systems. Verify that this testing period is in accordance with any reliability analysis previously carried out.

5. Confirm that a system is in place to manage the Register of Safety Related Devices (or equivalent), including identification of a document owner and technical authority.

6. Perform a thorough site inspection for hazards, housekeeping, and readiness for start -up.

7. Confirm that arrangements have been put in place for an extension to contracted services, where this is appropriate.

8. Review any procedures for special pre -commissioning and commissioning arrangements e.g. phased commissioning, temporary features.

9. Confirm that community relations aspects have been adequately considered.

10. Consider how the site will address the need for the Operate Stage HSE Review.

11. Confirm that necessary HSE regulatory requirements have been met.

4.

To

confirm

that

1. Confirm that emergency plans and procedures are in place and those roles and responsibilities along with channels of communication are clearly identified.

emergency

response

arrangements and

 

2. Confirm that a programme is in place to test the effectiveness of emergency response procedures and to feedback the lessons learned.

procedures

have

been

established

 

3. If appropriate, confirm the availability of a high level interface emergency plan which ties together the various

 

contingency plans. Links to

Local and National emergency services should be included.

4. Confirm that Safety Signs and escape route maps are in place and Assembly Points are demarcated as per KOC/ International Standards/Procedures/Best Practices.

5.

To verify that deviations

1. Review the project modification records and ensure that all design changes have been properly approved and recorded and updated in the operator’s hand-over documentation.

2. Confirm that aspects of the plant likely to influence HSE performance have not changed significantly throughout the project.

from design have been satisfactorily addressed and will not compromise HSE performance

3. Confirm that effects of a number of small changes do not introduce a significant HSE risk when considered together.

 

4. Confirm that changes identified in as built checks have been subjected to an appropriate hazard review process.

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 23 of 27

- Procedure for Project HSE Review (PHSER) Page 23 of 27 Supplemental Guidewords   1.5 Readiness

Supplemental Guidewords

 

1.5

Readiness of protective

2.2

Completion of safe work

3.4

Assurance of safety

devices Baseline inspections complete

practices procedures (hot work, vehicle entry, line

breaking, confined space entry, bypassing safety devices, etc)

instrumented systems

3.6

Access / escape routes

Safety equipment ready

1.7 Labeling

3.11 Regulatory approvals of permits Environmental monitoring

1.8

Availability of as -built

2.3

P&Ids and other documentation Availability of control system cause/effect diagrams and loop documentation Deviations from standards

Support (Laboratory,

workshops, stores, spares, vendors, contract services)

3.2

Occupational health

4.1

Access / escape routes

baselines

4.3

Integration with

Medical support

corporate

3.3

Pre-commissioning (Test

emergency response

2.1

Completion of

results)

5.1

Change register (scope

mechanical integrity/inspection and evacuation procedures. Completion of standing instructions (safety,

accident,

Test dossiers

changes, design changes,

Loop tests

field

changes)

fire fighting)

Information Sources

Construction Stage PHSER report and Project responses HAZOP recommendation closure documentation Pre-commissioning and test dossier. Plant/facilities organization and manning. Commissioning plan. Operating instructions. Maintenance instructions. Mechanical integrity and inspection procedures Emergency procedures (internal and external). Safety and fire fighting procedures and instructions. Punch list of incomplete construction items. List of items not accepted by Operator. Project commissioning engineers report. Operator training manual. Operator selection and training records Register of safety related devices (or equivalent) As-built P&Ids Control system cause/effect diagrams and loop drawings Approved permits Health Management plan

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 24 of 27

- Procedure for Project HSE Review (PHSER) Page 24 of 27 APPENDIX 6: PHSER #6: Project

APPENDIX 6:

PHSER #6: Project Operate & Monitoring Stage HSE Review (~12 months after Commissioning)

 

Objective

 

Team Activity

1.

To

verify

that

HSE

1. Confirm that any recommendations arising from all previous Project HSE Reviews and other HSE studies have been addressed and actions implemented and closure documented.

performance

of

the

operating

facility

meets

2. Review the modification record post start -up.

design intent

 

3. Ensure that isolating a system or segment of the facility for operational or maintenance need will not adversely affect the safety & integrity of the plant.

 

4. Review any design, operations or maintenance related problems and incidents and the measures taken to overcome them.

5. Review the actual emissions profile and compare with design values.

6. Confirm that all elements of KOC HSEMS have been established.

2. To ensure that lessons learned from the execution of the project and early operation of the plant are captured and shared.

1. Identify “lessons learned” from the development and ensure that they are widely shared, e.g. through the “KOC HSEMS” website, Group HSE Resource etc.

Supplemental Guidewords

1.1 Action tracking

1.3 Inspection results Reliability Occupational health Community relations

1.5 Compliance statutory requirements

1.2 Punch lists

Changes design Changes operations

 

Information Sources

All previous HSE Review reports List of modifications carried out post- commissioning Data on accidents, incidents, community complaints Operations, maintenance and inspection reports Occupational health data Environmental monitoring reports

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 25 of 27

- Procedure for Project HSE Review (PHSER) Page 25 of 27 APPENDIX 7 PHSER Worksheet Template

APPENDIX 7

PHSER Worksheet Template

Objective : <State the objective being reviewed>

Activity

Documents /

Findings

Recommendations

Action by

Due Date

Drawings

Reviewed

<State the

<Identify the documents / drawings which were reviewed in connection with the stated activity>

<List the

<List the Recommendations>

<Identify Responsible party (KOC/PMC/E&C Contractor)>

<Identify due date for action close-out>

activity within

findings of

the objective

the review>

 

which is

being

 

reviewed>

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 26 of 27

APPENDIX 8: Typical PHSER Report Format

Page 26 of 27 APPENDIX 8: Typical PHSER Report Format The report should be concise, maintaining

The report should be concise, maintaining a balance of positive comment along with identification of areas for improvement. The structure of the report should cover the areas identified below:

Front Page

Title

 

Client

 

Distribution

 

Report issue date

Management Summary

Review Purpose

 

Scope

 

Conclusions

 

Major findings

Detail of Report

Team members

 

Review dates

 

Text including main points / Worksheets

 

Findings

 

Recommendations

Appendix-1

Terms of Reference

Appendix-2

Index of Findings / Action Plan

Appendix-3

PHSER stage activities

KOC.GE.050 - Procedure for Project HSE Review (PHSER) Page 27 of 27

- Procedure for Project HSE Review (PHSER) Page 27 of 27 APPENDIX 9: Typical PHSER Terms

APPENDIX 9: Typical PHSER Terms of Reference

Project KOC XXX Stage HSE Review Terms of Reference

Review Process A Project HSE Review Team has been established to conduct a XXX Stage review of Project <fill in project number> in accordance with KOC PHSER Procedure. Identify, where appropriate:-

· Combination of review stages

· Specific tasks postponed from earlier review stages, or brought forward from subsequent review stages

Review Team List the review team, their roles (e.g. PHSER Chairman, Instrumentation Specialist etc.), their job titles and their work base. KOC personnel participation as against their contractors is essential.

Scope of Review

List:-

· Sections of the project that are to be included in the scope

· Sections of the project that are specifically excluded

· Scope details of any interfaces with existing facilities or parallel projects

Review Objectives Typically this list should reflect any combination of review stages.

Review Schedule Identify meeting locations (e.g. Design Contractor Office, construction site etc.), and schedule (e.g. start of review period, deadline for completion of review).

Review Deliverables

Identify for example requirements for:-

· Categorized recommendations

· Interim report

· Full report

· Special client requirements

Review Initiator