HSE - 5.7 Procedure for Pre-startup Safety Review Management

CNPC International

Doc. Title: Procedure for Pre-startup Safety Review Management Doc. Type: Procedure Custodian: Corporate HSE Department

Doc. No.: CNPCI Corp HSE – 6.5 Revision: 2.0 Issue Date: July 2012

Table of Contents 1. Objectives, Objectives, Scope and Application ........................................................ .............................................................................. ........................... ..... 1

1.1 Objectives ....................................................... ............................................................................. ............................................. ........................................ ................. 1 1.2 Scope ............................................ .................................................................. ............................................ ............................................ .................................... .............. 1 1.3 Application ............................................................ .................................................................................. ............................................. ................................. .......... 1 2. Relevant Documents ......................... ............................................... ............................................ ............................................ ...................................... ................ 1 3. Terms and Definitions............................................ .................................................................. ............................................ ...................................... ................ 1 4. Responsibilities ............................................ .................................................................. ............................................ ............................................ ........................... ..... 2 5. Management Management Requirements ......................................... ............................................................... ............................................ ............................... ......... 2

5.1 Basic Requirements ................................. ....................................................... ............................................ ............................................ ......................... ... 2 5.2 Establishment of PSSR Teams ....................... ............................................. ............................................. ........................................ ................. 3 5.3 Items for Review ................................................ ...................................................................... ........................................... .................................... ............... 4 5.4 Process................................................. ....................................................................... ............................................ ............................................. ............................. ...... 5 5.5 Document Filing ........................... ................................................. ............................................ ........................................... .................................... ............... 7 5.6 Assessment .......................................... ................................................................ ............................................ ............................................. ............................. ...... 7 6. Audit, Renewal, Deviation and Training and Communication ..................................... ..................................... 7

6.1 Audit.................................................... .......................................................................... ............................................. ............................................ ............................ ....... 7 6.2 Renewal .......................................................... ................................................................................ ............................................. ........................................ ................. 7 6.3 Deviation .......................................... ............................................................... ........................................... ............................................. ................................. .......... 8 6.4 Training and Communication............................................ .................................................................. ........................................... ..................... 8 Appendix A PSSR Checklist (applicable to system overhaul and maintenance without changes) .......................................... ................................................................ ............................................ ............................................ ............................................ ........................... ..... 9 Appendix B PSSR Checklist (applicable to new, modified and expanded systems systems and systems subject to changes) .......................................................... ............................................................................... ........................................... ...................... 13 Appendix C PSSR Checklist (applicable to safety review before spud-in) spud -in) ..................... 28 Appendix D PSSR Checklist (applicable to safety review before penetrating into oil and gas formations) formations) ........................................................ .............................................................................. ............................................ .................................... .............. 39 Appendix E PSSR Report (sample) ..................................... ........................................................... ............................................ ......................... ... 41



Table of Contents 1. Objectives, Objectives, Scope and Application ........................................................ .............................................................................. ........................... ..... 1

1.1 Objectives ....................................................... ............................................................................. ............................................. ........................................ ................. 1 1.2 Scope ............................................ .................................................................. ............................................ ............................................ .................................... .............. 1 1.3 Application ............................................................ .................................................................................. ............................................. ................................. .......... 1 2. Relevant Documents ......................... ............................................... ............................................ ............................................ ...................................... ................ 1 3. Terms and Definitions............................................ .................................................................. ............................................ ...................................... ................ 1 4. Responsibilities ............................................ .................................................................. ............................................ ............................................ ........................... ..... 2 5. Management Management Requirements ......................................... ............................................................... ............................................ ............................... ......... 2

5.1 Basic Requirements ................................. ....................................................... ............................................ ............................................ ......................... ... 2 5.2 Establishment of PSSR Teams ....................... ............................................. ............................................. ........................................ ................. 3 5.3 Items for Review ................................................ ...................................................................... ........................................... .................................... ............... 4 5.4 Process................................................. ....................................................................... ............................................ ............................................. ............................. ...... 5 5.5 Document Filing ........................... ................................................. ............................................ ........................................... .................................... ............... 7 5.6 Assessment .......................................... ................................................................ ............................................ ............................................. ............................. ...... 7 6. Audit, Renewal, Deviation and Training and Communication ..................................... ..................................... 7

6.1 Audit.................................................... .......................................................................... ............................................. ............................................ ............................ ....... 7 6.2 Renewal .......................................................... ................................................................................ ............................................. ........................................ ................. 7 6.3 Deviation .......................................... ............................................................... ........................................... ............................................. ................................. .......... 8 6.4 Training and Communication............................................ .................................................................. ........................................... ..................... 8 Appendix A PSSR Checklist (applicable to system overhaul and maintenance without changes) .......................................... ................................................................ ............................................ ............................................ ............................................ ........................... ..... 9 Appendix B PSSR Checklist (applicable to new, modified and expanded systems systems and systems subject to changes) .......................................................... ............................................................................... ........................................... ...................... 13 Appendix C PSSR Checklist (applicable to safety review before spud-in) spud -in) ..................... 28 Appendix D PSSR Checklist (applicable to safety review before penetrating into oil and gas formations) formations) ........................................................ .............................................................................. ............................................ .................................... .............. 39 Appendix E PSSR Report (sample) ..................................... ........................................................... ............................................ ......................... ... 41



1. Objectives, Scope and Application 1.1 Objectives This procedure is intended to standardize the safety review of installations, equipment, facilities and processes before startup to ensure all the aspects which may prevent them from operating in a safe and environmental friendly way are identified and adequate safety controls are in place before startup. 1.2 Scope This procedure specifies the requirements for pre-startup safety reviews and for relevant audits, renewal, deviations, training and communication. 1.3 Application This procedure applies to the safety review activities for installations, equipment, facilities and processes before startup. This procedure applies to Headquarter of CNPC International (hereinafter referred to as CNPCI), Regional Companies and Operating Companies under the direct management of CNPCI (hereinafter referred to as “all companies”), as well as all the contractors and suppliers providing services to CNPCI Headquarter and all companies. Operating companies for which CNPCI has operational control shall implement this procedure or formulate their own procedures or implementation processes for pre-startup safety review management according to this procedure, incorporate them into the HSE management system of their own and strictly enforce compliance. Operating companies for which CNPCI has joint or no operational control shall formulate corresponding procedures with reference to this procedure. In case of any conflict between this procedure and the laws, regulations, standards and specifications applicable in the host country, the procedure to be implemented shall be developed upon the consensus of all the partners of the joint venture.

2. Relevant Documents 2.1 CNPC Corporate Standards Q/SY 1245—2009 Specification for Pre-startup Safety Review Management 2.2 CNPCI Corporate HSE Management System HSE – 2.0 HSE Management System Manual HSE – 6.8 Procedure for Process and Mechanical Change Management HSE – 4.9 Procedure for Process Hazard Analysis Management

3. Terms and Definitions 3.1 Pre-Startup Safety Review (PSSR) The process to review all the aspects which may prevent installations, equipment, facilities or processes from operating in a safe and environmental friendly way, ensure adequate safety controls are in place and all deficiencies requiring prior correction are corrected before startup, and then grant startup approval. 3.2 Deficiencies Requiring Prior Correction Deficiencies which are identified in the PSSR to be deviated from the design or operating codes and/or standards, may result in serious damage during or after start-up and threaten the safety and must be corrected before start-up. 3.3 Remaining Deficiencies

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Deficiencies which are identified in the PSSR to be deviated from the design or operating codes and/or standards, won’t hamper safe start-up of processes and equipment, but may have negative impact on start-up efficiency and product quality and result in safety and/or environmental accidents during operation, and could be corrected after start-up. 3.4 Area or Unit Chief A manager responsible for the operation safety of the process or equipment to be started, such as the head of a plant.

4. Responsibilities 4.1 Corporate HSE Department of CNPCI is responsible for formulation, management and maintenance of this procedure. 4.2 HSE management committees at all levels are responsible for reviewing and approving the plans and resources for the t he development, revision, communication, training and implementation of the Procedure for Pre-startup Safety Review Management, and for auditing and monitoring the overall implementation of the procedure to ensure the quality of the implementation. 4.3 Corporate functional departments of CNPCI are responsible for facilitating the promotion and implementation of this procedure. 4.4 All companies shall formulate, manage and maintain their respective pre-startup safety review management procedures according to this procedure. Relevant functional departments of all companies are responsible for the implementation of the procedures and shall provide corresponding training, supervision, measurement and assessment. 4.5 HSE departments of all companies are responsible for providing consultancy, support and audit for the implementation of their pre-startup safety review management procedures. 4.6 All grass-root units (plants, stations, crews, workshops, installations and facilities) shall implement the pre-startup safety review management procedures of their companies and provide suggestions for improvement of the procedure implementation. 4.7 All relevant staffs shall receive training for pre-startup safety review, implement prestartup safety review management procedures, participate in audits for pre-startup safety review, and provide improvement suggestions.

5. Management Management Requirements 5.1 Basic Requirements 5.1.1 Pre-startup safety review spans through project transfer and system operation. It is designed to identify all the aspects which may have impact on the safe operation of processes and equipment to ensure the following conditions are satisfied: ——construction and installation of equipment is in accordance with design specifications and established standards; ——procedures to guarantee the safety operation of equipment, such as safety, operation, maintenance, and emergency procedures, are in place; ——appropriate process hazard analyses have been completed and all the recommendations have been either implemented or addressed in a reasonable manner; ——management of change has been followed and process safety information havebeen updated;

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——each employee involved in operation or maintaining the process or equipment has been adequately trained and acquired the required certifications; ——All the requirements about process safety management have been met and all the deficiencies requiring prior correction have been resolved and such resolutions have been verified. 5.1.2 Pre-startup safety review is a prerequisite for project commencement. Projects requiring PSSR include but are not limited to: ——New, or modified or expanded systems (including leased systems); ——Modified processes or equipment which involve flammable, ex plosive, toxic or hazardous materials and high temperatures and high pressures; ——Facility shutdown and overhaul projects; ——Spudding or penetrating into oil and gas bearing formations or abnormally high pressure formations; ——Adoption of new processes or new technologies; ——Other projects such as restarting the operation of oil or gas plants or stations. 5.1.3 PSSR teams should be built according to the authorization level of the specific projects and conduct PSSR according to the checklists prepared in advance. 5.1.4 Considering the scale and work schedule of a project, PSSR may be conducted multiple times in different stages and by focusing on different areas. 5.2 Establishment of PSSR Teams 5.2.1 Team Composition 5.2.1.1 To guarantee the quality of a PSSR, a PSSR team should be established in advance according to the project schedule. A team leader should be designated depending on the authorization level of the project concerned (usually the project manager, production manager or chief engineer will act as the team leader). The team leader then proceeds with team member selection and work assignment. 5.2.1.2 A PSSR team may be consisted of employees specializing in process technology, equipment, inspection and maintenance, electric instruments, main operation and human resource as well as HSE professionals. The team should also include representatives from the contractors, parties involved in construction, design and supervision, and external experts with special expertise and experiences. 5.2.2 Work Assignment Area or Unit Chief —— establishing the PSSR team and providing professionals and other resources required by the PSSR of project; ——leading the development of PSSR checklists together with the PSSR team leader; ——chairing the PSSR planning meeting and review meetings; ——reviewing the resolutions for all deficiencies requiring prior correction and approving the startup of projects for which he/she has authority over upon confirmation together with the PSSR team of the completion of the correction of all deficiencies requiring prior correction; ——supervising, inspecting and following up the completion of the correction of remaining deficiencies; ——providing adequate resources for the implementation of all the safety and environmental measures before startup; ——ensuring all employees have received training in the PSSR management procedure.

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PSSR Team Leader ——developing and implementing the PSSR plan; ——organizing the PSSR planning meeting and review meetings, revising and improving the PSSR checklists; ——deciding on work assignments for team members and the work schedule; ——leading the PSSR and taking the responsibility for the quality of the PSSR; ——tracking and verifying the progress of the correction of all deficiencies requiring prior correction; ——preparing all the records and documents of the PSSE and filing them as required; ——obtaining support for professionals from the higher management as necessary. PSSR Team Members ——attending the PSSR planning meeting and review meetings; ——participating in preparation of PSSR checklists and conducting the PSSR against the prepared checklists; ——verifying the solutions for all deficiencies requiring prior correction and for remaining deficiencies; ——confirming the completion of the correction of all deficiencies requiring prior correction. Process Safety Management Coordinator Production Department or Operation Department may appoint a person who has received training in process safety and risk management, process safety analysis and PSSR and is familiar with process safety analysis methods to act as the process safety management coordinator of the project to be responsible for ——coordinating and guiding the preparation of the PSSR checklists by the production and operation units ——organizing the training in PSSR implementation methods ——coordinating the implementation process of a PSSR ——reviewing completed PSSRs for integrity and contents ——assisting in preparing and filing the documents of PSSRs HSE Professionals ——participating in the preparation of JSST checklists; ——assisting in staff training in PSSR; ——participating in the inspection for specialized HSE facilities and the review for the implementation of HSE requirements. 5.3 Items for Review The PSSR team shall prepare the PSSR checklists together with the process safety management coordinator, taking into account the nature of the operation, the characteristics of the process and equipment, etc. The PSSR checklists in Appendix A, B, C and D may be referred to and items for review may be added or revised as necessary. The checklists should cover process, technology, personnel, equipment, accident investigation, emergency response, environmental protection, etc. 5.3.1 Process and Technology ——All the process safety information (e.g. material safety data sheets, process equipment design basis, plot plans, piping & instrument drawing, certifications, etc.) have been updated and

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filed; ——Process hazard analysis recommendations have been implemented; ——Operation procedures, operation cards and relevant safety requirements comply with the requirements for processes and technologies and have been approved; ——Changes to processes and technologies, including changes to processes and instrument drawings, have been approved and recorded; ——Public utilities are ready for the startup of the project; ——The production and operation command system functions well. 5.3.2 Personnel ——All staffs involved have received trainings about the startup plan, HSE hazards, operation procedures, maintenance procedures, safety specifications and emergency response; ——Contractor staffs have received HSE training corresponding to their work, including hazards of potential fire, explosion or release of toxic substances in the workplace or the surrounding area as well as emergency response; ——Newly hired or transferred staffs are clear about the possible risks associated with their work and are competent in their work. 5.3.3 Equipment ——Equipment has been made, transported, stored and installed according to design specifications; ——Equipment inventory and records of equipment operation, inspection, repair and maintenance have been established as required and items, procedures and frequencies for equipment testing and inspection comply with the relevant requirements; ——Risks caused by changes to equipment have been analysed, procedures to guarantee the safety of equipment startup and operation, such as equipment startup plans, operation procedures, maintenance procedures, safety specifications and emergency response plans, have been updated and distributed to relevant people and the provisions in HSE – 6.8 Procedure for Process and Mechanical Change Management has been followed. ——All the other auxiliary systems are ready. 5.3.4 Incident Investigation and Emergency Response ——Corrective measures based on lessons leant from previous incidents have been implemented; ——Emergency response plans are in consistency with process safety information and staffs involved have received training about emergency response plans. 5.3.5 Environmental Protection ——Emission and discharge reduction equipment can operate normally; ——Waste (including commissioning wastes and defective products) treatment practices have been determined; ——Environmental incident response procedures and resources (people, equipment, materials, etc.) are in place; ——Environmental laws, regulations and standards applicable in the host country and the environmental policies and procedures of the Company are complied with. 5.4 Process 5.4.1 Planning Meeting The Area or Unit Chief and the PSSR team leader shall call all team members for the PSSR

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plan meeting. The main contents of the meeting are as follows: ——A general introduction to the project by the PSSR team leader; ——A clear definition of the work scope of the PSSR; ——Review of the contents of the PSSR checklists; ——Work assignments to individual team members by the PSSR team leader; ——Development of the PSSR schedule; ——Establishment of a mechanism for coordination with relevant parties involving in engineering design, construction, etc., and o ther resource support. 5.4.2 Implementation of the PSSR 5.4.2.1 PSSRs include both document reviews and site inspections. PSSR team members shall review against the PSSR checklists item by item according to their work assignments and document all the findings with clear indications of the items reviewed, locations where the reviews are conducted and people who perform the reviews. 5.4.2.2 To guarantee the quality of a PSSR, before the equipment installation work is completed, preparation for the PSSR should be started, PSSR checklists should be developed and the PSSR may be conducted for multiple times by stages and by disciplines according to the construction progress of the project. All the issues identified from the reviews should be reported to departments concerned for a timely solution. It will be too later to start the PSSR after the completion of construction of the project. 5.4.3 Review Meetings 5.4.3.1 Having completed the review of all the items in the PSSR checklists, the PSSR team leader and the Area or Unit Chief shall call all team members for the PSSR review meeting to present and analyse the results of the PSSR: team members report their findings from the PSSR, conduct process safety analysis to each finding, divide the findings into deficiencies requiring prior correction and remaining deficiencies, draft a PSSR report and confirm the items to be corrected before and after the startup and the deadline for such corrections to be made. 5.4.3.2 A PSSR report shall include the following: ——The date of the report and an identification of the covered process and equipment, the process safety information, and standard operating procedures reviewed; ——An identification of the codes and standards upon which the covered process design and operations were based; ——The names of the persons who performed the safety review; and ——Deficiencies from the design and operating codes and standards which were found during the PSSR and shall be corrected before or after the startup with an appropriate description of the resolution of each deviation finding; ——Signatures of people for confirmation or approval and report distribution records. Refer to Appendix E for a sample of a PSSR report. 5.4.3.3 For a PSSR implemented several times by stages and by disciplines, a holistic PSSR review meeting shall be held before the startup of the project to sort, review and reconfirm the PSSR results from all the reviews performed and a comprehensive PSSR report shall be drafted on this basis. 5.4.4 Follow-up and Approval of Startup 5.4.4.1 Departments concerned shall bring forward deviation correction requirements in the form of hazard elimination notices or non-compliance correction reports and track and verify the

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results of the corrections. Production and operation departments shall supervise the process of PSSRs. 5.4.4.2 All deficiencies requiring prior correction must have correction plans including corrective measures, responsible person(s) or units, schedules for correction and deadlines for correction completion. The Area or Unit Chief should hold regular (generally once a week) review meetings together with the PSSR team to follow up the progress of the correction of deficiencies requiring prior correction until they are all corrected. 5.4.4.3 Upon completion of the correction of all deficiencies requiring prior correction, the Area or Unit Chief should review the correction results with the PSSR team. Upon acceptance of the correction results, the PSSR team leader should confirm in the PSSR checklists and report and pass them to the Area or Unit Chief. 5.4.4.4 The Area or Unit Chief may approve the PSSR report only after having confirmed that all deficiencies requiring prior correction have been corrected and all remaining deficiencies have got monitoring measures and correction plans with designated responsible person(s) (or units) and deadlines for completion. For a project sponsored by the area or unit itself, the project may be started upon the approval of the PSSR report. For a project sponsored by the upper level of management, the approval of the PSSR report by the Area or Unit Chief is a pre-requisite and a primary condition for the startup and acceptance of the project. 5.4.4.5 After project startup, the PSSR team leader and the Area or Unit Chief should continue to track the progress in the correction of remaining deficiencies and make acceptance upon the completion of their corrections. After acceptance, the PSSR team leader should record the date of completion on the PSSR checklists and report. 5.5 Document Filing All the documents concerning the PSSRs performed, including PSSR checklists, PSSR reports, correction plans for remaining deficiencies and follow-up plans, shall be filed. The drawings, design documents and other data for deficiencies involving changes should be updated and filed. Upon completion of the correction of remaining deficiencies, the responsible person should send a written notice to the Area or Unit Chief. The written notice should be filed together with the PSSR checklists, PSSR reports and process hazard analysis reports of the project to ease future document searches. 5.6 Assessment After completion of a PSSR, the process safety management coordinator should assess the PSSR performed for integrity and contents.

6. Audit, Renewal, Deviation and Training and Communication 6.1 Audit CNPCI Headquarter and all companies shall audit the management of pre-startup safety review as an important part of their HSE audit programs and may conduct audits solely focused on the implementation of the procedure if necessary. 6.2 Renewal This procedure shall be reviewed and revised by its custodian as necessary and, at a minimum, not later than five years from the date of the last revision.

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6.3 Deviation All companies shall report to Corporate HSE Department of CNPCI for any deviation from this procedure in their own pre-startup safety review procedures. Any deviation in the implementation of the procedure shall be authorized by direct supervisors. Deficiencies shall be documented and the documentation must include the relevant facts justifying the deviation decision. Deviation authorization must be renewed annually. 6.4 Training and Communication This procedure should be communicated throughout CNPCI. All relevant staff, including contractor workforce, should be provided training as appropriate. Training records must be maintained.

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Appendix A PSSR Checklist (applicable to system overhaul and maintenance without changes) Table A PSSR Checklist (applicable to system overhaul and maintenance without changes) Production Unit / Equipment Brief description of the overhaul and maintenance project

The whole category is not applicable

Remove all unnecessary materials used in overhaul and maintenance

Select Irrelevant

Deficiencies requiring actions

Relevant

Remaining deficiencies

Deficiencies requiring prior correction

Review results or requirements for correction

1. Operating platforms / scaffolds 2. All items removed as wastes or replaced after maintenance 3. Hydraulic test equipment temporary equipment

and

other

4. Temporary connection pipes, hoses, power lines, signs/markings, etc. 5. Leftover and unnecessary materials for maintenance 6. Other materials that need clearing The whole category is not applicable

Fire fighting devices and safety facilities

Select Irrelevant

Deficiencies requiring actions Relevant

7. Inspect or test fire fighting devices and safety facilities. 8. Replace or repair lost or damaged fire fighting devices and safety facilities identified during inspections or testing. 9. Record the inspection and test results of fire fighting devices and safety facilities as necessary. 10. Check if all measuring instruments and meters are verified correctly by authorized agencies, within their valid periods and have correct indications. 11. Check if all safety protection facilities are restored. 12. Check if all relevant warning signs are restored.

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Table A (Continued) The whole category is not applicable

Check process pipelines and equipment overhauled or maintained

Select Irrelevant

Relevant

Deficiencies requiring actions Deficiencies Remaining requiring prior deficiencies correction


1.3 Check the shutdown process record of critical equipment, confirm that the person responsible for the equipment has signed and filed the record and confirm if the shutdown process complies with the shutdown procedure. 14. Install all plugs (screw plugs or blind plates) properly 15. Confirm that all valves are set at correct positions. 16. Check the air-tightness of all connection parts related to the maintenance. 17. Check the blind plate checklist and attach a signed copy of the checklist to this report The whole category is not applicable

Flanges

Select Irrelevant





18. Check the tightness of all bolts. 19. Check if bolt gaskets are appropriate and complete. 20. Check if flange gaskets are placed at correct positions. 21. Check if flanges have any damage. The whole category is not applicable

Valves

Select Irrelevant


22. Does replacement or adjustment of packing meet the requirement? 23. Check if packing is sufficient. 24. Check if valves are set at correct positions. 25. Conduct and confirm loop tests on control valves. 26. Check if travels and failure positions of all control valves are correct. 27. Check if all control valves are under the control of the control system.

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Table A (Continued) The whole category is not applicable Select

Safety valve Irrelevant





28. Safety valves are within valid periods of inspection and have inspection labels. 29. Rated pressures of safety valves do not exceed the designed pressures for vessels, containers, pressure pipes and equipment. 30. Isolation valves of safety valves have been opened completely. 31. Isolation valves have been locked or sealed. 32. If possible, verify if isolation valves are really opened. The whole category is not applicable

Items to be confirmed for overhauls due to accidents

Select Irrelevant





33. Check if the causes of the accident have been found. 32. Check if the causes of the accident have been eliminated. 35. Check if operation staffs have learnt the lessons from the accident. 36. Check if measures to prevent reoccurrence of the accident are in place. The whole category is not applicable

Auxiliary materials for start-up

Select Irrelevant



37. Check if auxiliary materials meet the standards for the process or equipment. 38. Check if auxiliary materials meet the requirements for the process and equipment and are adequate in quantity.

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Table A (Continued) The whole category is not applicable

Other relevant systems (power, cooling and circulating systems)

Select Irrelevant


Remainin g deficiencies



39. Check if relevant systems meet start-up requirements. 40. Check if power systems have passed pre-startup insulation tests and seal heads meet explosion proof requirement. The whole category is not applicable

Other inspection items

Select Irrelevant

Relevant

Deficiencies requiring actions Remaining deficiencies



41. Confirm if all operation and maintenance procedures meet the requirement. 42. Check if operators have obtained operation procedures for start-up of relevant equipment, received training and acquired corresponding qualification certificates. 43. Exchange opinions on the inspection with maintenance staffs and the person in charge of maintenance and reach a consensus that all tasks have been completed. Overhaul or maintenance work reviewed by: Date:

Technology reviewed by: Date:

Safety reviewed by: Date:

Operation reviewed by: Date:

Area or Unit Chief: Date:

Others: Date:

Brief description of approaches used in equipment/process start-up

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Appendix B PSSR Checklist (applicable to new, modified and expanded systems and systems subject to changes) Table B PSSR Checklist (applicable to new, modified and expanded systems and systems subject to changes) Production Unit/ Installation/ Equipment

Time of review

Reviewed by Brief description of the project under review:

The whole category is not applicable Select

Personal safety and health Irrelevant

Relevant

1. Is personal protection equipment (PPE) adequate? 2. Does the PPE provided meet the requirements for controlling the hazards at site? 3. Is PPE put at an appropriate and easily accessible place? 4. Is PPE certified to be qualified and within the valid period? 5. Have noise reduction measures been adopted or clear warning signs been placed at high noise areas? Are staffs equipped with earplugs? 6. Is the lighting adequate? 7. Are there walkways or ladders or stairs leading to platforms at height? 8. Are walkways or working platforms made anti-slip and equipped with safety protective devices, such as rails and fences? 9. Are safety measures required for working at heights in place? 10. Do workplaces have adequate ventilation? 11. Do sight holes, flow directions and meter glasses meet safety requirements? 12. Have working platforms / scaffolds b een cleared? 13. Have all the wastes or replaced materials been cleared? 14. Have hydraulic test equipment and other temporary equipment been cleared? 15. Have temporary connection pipes, hoses, power lines, signs and markings, etc., been cleared? 16. Have unused and unnecessary materials been cleared?

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Table B (Continued) 17. Have any other materials requirin clearance been cleared? 18. Are there enough signboards or fences to clearly mark working areas or dangerous zones? 19. Are exits clearly marked? 20. Has personal exposure to chemical materials during clearing and maintenance been minimized? 21. Are storage areas clearly marked? Are there any clearly written procedures governing the loading/offloading and use of compressed gas cylinders? 22. Is there any measure to prevent people from contact with high/low temperature and high/low voltage power supply? 23. Are materials placed in order and easily accessible? 24. Are vessels, storage tanks and operation equipment clearly marked? 25. Has equipment out of service been isolated or marked? 26. Can safety showers and eye wash equipment work well? 27. Are positive pressure respirators adequate in number, meeting relevant standards and in good and reliable working conditions? 28. Is the connection for nitrogen system different from that for instrument air? 29. Are confined spaces at site clearly marked? 30. Are audio and visual alarms certified to be qualified, within the valid period and can function well? 31. Is there a checklist and reaction matrix or safety instruction for chemicals within the area? 32. Is entry into production areas controlled? 33. Are “Do Not Touch” signs clear and conspicuous? 34. Are all the MSDSs the latest? Can they be found at site? 35. Are material hazard training materials and communication procedures the latest?

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Table B (Continued) The whole category is not applicable Deficiencies requiring Review actions results or Deficiencies Remaining Irrelevant Relevant requiring prior requirements deficiencies for correction correction Select

Process and equipment safety

36. Have process and equipment start-up plans been prepared and approved? 37. Are temporary safety measures in the start-up plan in place? 38. Has equipment been equipped with pro tective devices as required? 39. Are there latest MSDSs for lubricating oil and sealing liquids? 40. Check if auxiliary materials meet process and equipment standards. 41. Check if auxiliary materials meet process and equipment requirements and are adequate in quantity 42. Are the loading capacities for floors, guide rails, triangle derricks and lifting slings clearly marked? 43. Can equipment be cleaned, isolated and maintained? 44. Are operation steps for key v alves specified in the process flow? 45. Can valves be locked according to the lockout/tagout procedure? 46. Are valves easy to access for op eration purpose? 47. Are required isolations placed at intersections of pipelines containing different materials? 48. Are pipelines checked one by one as required? 49. Have pipe sections out of service been isolated or removed? 50. Are sewage discharge and venting points at locations easy to see and operate? 51. Are sampling points at locations easy to see and operate? 52. Are sampling points enough? 53. Are pipelines properly supported as requ ired? 54. Are cantilever connections supported? 55. Are all pipeline supports in close contact with the pipelines and bearing even weight? 56. Are pipeline expansion absorption devices and measures in place? 57. Does the use of hoses and flexible connections meet safety requirements? 58. Have backflow prevention devices (check valves) been installed? 59. Are locations, directions and angles of check valves installed correctly? 60. Are locations, directions and angles of filters installed correctly? Are they easy to open and clean? 61. Are temporary connection pipe sections of appropriate length? 62. Have static jumpers and groundings been installed on pipelines as required? 63. Have cathodic or anodic protections installed for underground pipelines? 64. Are insulations used for mandatory cathodic protections to prevent electric current from entering other pipelines and equipment?

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65. Have items 62, 63 and 64 been tested? Have test records been filed? 66. Have pressure test liquids, chemical cleaning liquids and neutral liquids for commissioning in pipelines and equipment been cleaned? 67. Are gaskets fit for the materials and temperatures of the process? 68. Are gaskets fit for the pressure levels of valves and pipelines? 69. Do gaskets and flanges match the connections of equipment? 70. Are flange gaskets placed at correct positions? 71. Check if flanges have any damages. 72. Have air-tightness tests been conducted for flange connections? 73. Check if bolt gaskets are appropriate and complete. 74. Does installation of bolts and nuts meet relevant requirements? Do they become loose? 75. Do release points for safety valves lead to safe positions? (Posing no threat to either people or equipment) 76. Are release pipes for safety valves adequately supported and fixed? Do pipe d iameters meet relevant requirements? 77. Have isolation valves of safety valves been opened completely? 78. Have isolation valves of safety valves been locked or sealed? 79. If possible, verify if isolation valves are really opened. 80. Are locking/unlocking valves in process pipelines at correct status and locked? (To avoid formation of enclosed pipe sections and mixing of different materials) 81. Do safety valves of direct discharge type have weep holes and rain hats? 82. Are isolation valves of release valves in unlock state? 83. Are status checklists for isolation valves of release valves the latest? 84. Do new pressure settings for safety valves meet relevant requirements and communicated to operation and maintenance staffs? 85. Have vibration abatement devices for pipeline equipment been installed? 86. Have fix bolts for expansion joints been loosened? 87. Have protective covers and rails for moving/rotating parts been installed? 88. Have radiation equipment been protected as required? 89. Have lockout/tagout points been locked and tagged? 90. Are serial numbers of equipment and instruments are clear and easy to read? 91. Are blind p lates and spectacle blinds correctly installed, numbered, tagged and registered? 92. Are discharge points equipped with receiving trays (pools) and installed with blind plates or screw plugs? 93. Have thermal insulations been completed as designed? 94. Are three-way valves correctly marked? 95. Are pressure and temperature meters and flow indicators installed at positions easy for reading? 96. Are all measuring instruments and meters certified to be qualified,

16



within the valid period and with correct indications? 97. Have equipment lub rication jobs been completed? 98. Is the process safety management procedure the latest version and does it cover additional equipment and changes?

Table B (Continued) The whole category is not applicable Select


Electric safety Irrelevant

Relevant


99. Does electric equipment comply with the standard for explosion proof level of the area? 100. Can start and shutdown switches and electric switch cabinets be differentiated from their tags? 101. Are there as-built drawings of electric lines? 102. Are power use permits and work permits approved? 103. Are fittings for conducting wire guide tubes sealed? 104. Have power indicator lights passed tests? 105. Have electric grounding for power equipment passed tests? 106. Do electric lines meet the requirements for load and laying? 107. Have insulations for electric lines passed tests? 108. Have all the required electric safety devices been provided and certified to be qualified? 109. Are safety protective devices for electric equipment installed as required? 110. Has motor steering been examined? 111. Have electric interlocks passed function tests? 112. Have electric insulation and temperature rise passed tests? 113. Have electric protection relays and safety devices been installed and tested? 114. Has staffs be provided training on lockout / tagout management procedure? 115. Are lockout/tagout points fixed?

17






Control System Irrelevant Relevant

116. Has the fault state of emergency shutdown (ESD) valves and control valves been confirmed both at site and in the control room? Are they matching each other? 117. Have functional tests been conducted for ESD valves? 118. Has bypass function of the ESD valves been confirmed to be unblocked? 119. Is the causal relation of the ESD system the latest? 120. Have loop and functional tests been conducted for automatic control valves? 121. Are travels and failure positions of all control valves correct? 122. Are all control valves under the control of the control system? 123. Have new critical instruments and analysers been calibrated and verified? 124. Are there as-built drawings for loop and analyser control logics? 125. Have new critical instruments been covered by monitoring, maintenance and repair plans? 126. Can automatic valves be isolated for maintenance purpose? 127. Have pressure, temperature, liquid level and flow control meters been calibrated and verified? 128. Are system alarm checklists the latest? 129. Is there a procedure for regular test of alarm interlocking logic? 130. Have alarms and interlocks passed tests? 131. Have alarm and interlock documents been filed? 132. Is there a procedure for maintenance of alarm and interlock devices? 133. Have computer failures of the control instrument system been addressed in both the operation procedure and emergency response procedure? 134. Can the computer controlling the ESD system and the computer controlling the distributed control system (DCS) for process operations work independently? 135. Are trigger sensors of the ESD system independent from the op erating control system?

18






Table B (Continued) The whole category is not applicable

Ergonomics

Select

Irrelevant Relevant

Deficiencies requiring actions Remaining eficiencies

136. Are control buttons, switches and valves convenient for operation? (Avoid excessive stretching or bowing) 137. Are display screens and con trol panels easy to see, understand and operate? 138. Has heavy manual handling been minimized? 139. Have glare and reflection from working surfaces and screens been removed? 140. Are work spaces for operators and maintenance staffs big enough and comfortable? i.e. big enough for them to stand up, turn around and bend 90 degrees with one foot on the ground and both hands holding one ankle. 141. Are emergency alarms resistant from interference by process operation noise? Can staffs hear emergency alarm at any location? 142. Have repetitive forced actions (e.g. rhythmic movements following machines) been minimized? 143. Have manual handling of toxic and hazardous materials been minimized? 144. Has the time for staffs to wear PPE, such as chemical protective clothing and positive pressure respirators, been minimized?

19

Deficiencies equiring prior orrection





Fire control

Select Irrelevant

Relevant

145. Have fire walls and fire doors been constructed and installed? 146. Do fireproof materials meet relevant requirements? 147. Are fire extinguishers equipped according to required quantity, types and locations? 148. Are fire extinguishers put in right places and numbered? 149. Have registration and inspection records for new fire extinguishers been established as required? 150. Do fire control facilities meet the requirements for quantity, capacity and locations in the design? (such as water sprinkling systems, automatic fire extinguishing devices, fire hydrants, etc.) 151. Have fireproof layers been installed below cable bridges as necessary? Have water sprinklers been installed above cable bridges as necessary? 152. Have water sprinkling, fire water and automatic fire extinguishing systems passed system function tests? 153. Are pipelines for water sprinkling, fire water and automatic fire extinguishing systems adequately supported? 154. Are drainage valves installed for potential water accumulation sections in water sprinkling, fire water and automatic fire extinguishing systems? 155. Are fire control system diagrams the latest? 156. Are water sprinklers facing the correct direction? 157. Do flammable gas monitoring devices installed meet the requirements for quantity, location and height? Have they been verified to be qualified? 158. Does storage of flammable liquids meet fire control requirements? 159. Does fire engine access meet the requirements in the original design? 160. Is fire engine access unblocked? 161. Are there dedicated or part-time fire brigades? Is there a regular fire drill plan? 162. Have fire fighting systems been accepted by the fire control authority?

20







Process safety information

Select Irrelevant

Relevant




163. Is there an established procedure for process safety information management? 164. Are the MSDSs of all materials ready, updated and accessible? 165. Have chemical reaction matrices or specifications been developed or updated? 166. Are management standards for toxic and hazardous materials ready? 167. Have as-built drawings of processes and equipment been filed and updated? 168. Have technical materials of processes and equipment been filed and updated? The whole category is not applicable

Process and mechanical changes

Select Irrelevant

Relevant


169. Did all changes follow the procedure for process and mechanical changes? Have they been checked? 170. Have all technical items related to process and mechanical changes been checked? 171. Have all the people responsible for the project signed the change application form for confirmation? 172. Has the procedure for process change management been applied to all changes? 173. Have all the items of change related to operation been completed? 174. Have approval processes required for operation and maintenance been implemented for the change? 175. Are documents required by the change the latest version? 176. Are trainings required by the change completed? 177. Have temporary protective devices used in the process of change been removed?

21






Process hazard analysis Irrelevant Relevant



178. Have process hazard analyses been conducted for new and modified systems? 179. If yes, have recommendations proposed in process hazard analysis reports been implemented? 180. Has the process safety coordinator filed all recommendations? 181. If lack of process hazard analyses, have recommendations based on pre-startup hazard and environment aspect identification been implemented? 182. Have recommendations from process risk analyses required by changes been implemented? 183. Has all process safety information related to changes been updated? Including operation manuals, alarm parameters, additional safety equipment, deviations, set values, upper and lower safety limits in normal operation, etc. 184. Have people directly responsible for processes and equipment got all the process safety information they need? 185. Has the process risk analysis report been completed? 186. Does the process risk analysis report reflect changes in the construction process? The whole category is not applicable

Incident investigation

Select Irrelevant

Relevant

187. Is this new or modified project required by the analysis results of previous accidents? 188. If yes, have all the recommendations been implemented? 189. If yes, have all the recommendations been documented and filed by the process safety coordinator? 190. Have the accident investigation report and recommendations been communicated to relevant operators? 191. Have the contents of the accident investigation report and recommendations been communicated to equipment maintenance staffs? 192. Have maintenance related recommendations in the accident investigation report been implemented? 193. Have recommendations in accident analysis reports of similar processes or equipment been implemented on the processes and equipment under review?

22







Mechanical integrity

Select

Irrelevant

194. Is there a repair and maintenance procedure for all equipment? 195. Has the quality and quantity control procedure for maintenance materials and spare parts been developed and approved? 196. Have critical equipment maintenance tracking records been established? 197. Have the inspections and testing of the following equipment been completed? Have the records been filed? Has regular testing during no rmal operation been included in the maintenance plan? (1) Pressure vessels (2) Pressure release and venting devices (3) Control equipment, control logic and alarms (4) Emergency response equipment, including emergency shutdown and isolation devices or systems (5) Firefighting facilities (6) Pipelines for transporting toxic and poisonous materials (including valves, restrictor valves, expansion joints, hoses, etc.) (7) High speed turbines, centrifugal separators and other high speed rotary devices (8) Material intake connectors of key process pipelines (9) Electric and static groundings and static jumpers (10) Emergency alarm system (11) Monitoring instruments and sensors (for pressure, temperature, flow, etc.) (12) Pumps (13) Hoisting and lifting equipment (14) Ventilation systems 198. Have statutory inspections and tests been certified by relevant regulatory authorities (or third parties) (e.g. for pressure vessels, hoisting and lifting equipment, firefighting equipment, etc.)? 199. Have all commissioning and testing preparations been completed? (1) Hydraulic tests (2) Air tightness tests (3) Chemical cleaning, passivation, etc. 200. Can spare parts of process pipelines and equipment meet the minimum storage requirement? 201. Has an equipment lubrication plan been developed based on equipment lubrication requirements?

23

Relevant






Quality assurance

Irrelevant

Relevant



202. Have equipment provided by suppliers been verified to meet the parameters in design specifications? 203. Has installation of critical equipment been confirmed to meet the parameters in design specifications? 204. Has installation of critical equipment been confirmed to meet the requirements in the equipment technical specifications from the supplier? 205. Does the equipment quality inspection report, including equipment manufacturing, assembling and installation, comply with the quality assurance management plan of the project? Has the report been filed together with design documents? 206. All members of the JSSR team have conducted site inspections and reached a consensus or signed for confirmation that: (1) Installation of all equipment meets the requirements in design documents. (2) Installation of all process pipelines is consistent with the drawings. (3) Installation of all gaskets meets the requirements in design documents. (4) Support to and fixation of all pipelines meet design requirements and are adequate. 207. The JSSR team has confirmed at site that the use of all low temperature materials (including containers, pipelines, gaskets, flange bolts, etc.) meet the requirements in design documents. The whole category is not applicable Select

Operating procedures

Irrelevant

208. Have safe work specifications (safety management standards for high risky operations) been formulated, updated and approved? 209. Have all safety related requirements during operations (high risky job performance) been included in operating procedures? 210. Are there any new safe operation requirements to be added to operation procedures after changes to equipment? 211. Is it necessary to test updated operation procedures with water, chemical solutions or other safe neutral solvents? 212. If necessary, is there any operation procedure to provide assurance? 213. If the test proves that the procedure or the equipment fails to meet the requirements, will the operation procedure o r deficiencies of the equipment be corrected? 214. Have operation procedures for processes and equipment

24

Relevant





been formulated, updated and approved?


Training / Competence Assessment

Select Irrelevant

Relevant




215. Have operation staffs (including DCS operators) received training on skills required by their jobs? Are their skills? 216. Have maintenance staffs (including mechanical, instrument and electric maintenance staffs) received training on skills required by their jobs? Are their skills verified? 217. Have managers/supervisor received training on skills required by their jobs? 218. Have special operation staffs obtained work certificates required by the special operation they perform? Are their certificates valid? The whole category is not applicable

Contractors

Select Irrelevant

Relevant




219. Are training materials for contractor staffs ready? 220. Have contractor staffs received training on skills required by their jobs? 221. If the project involves changes to a system, have training materials for contractor staffs been upgraded or updated? 222. Have management controls for access to production areas and operation performance by contractor staffs been finalized and implemented? The whole category is not applicable

Management of personnel change

Select Irrelevant

Relevant

223. Have all staffs involved in job changes (change of job, promotion, new employee, etc.) been trained, assessed and confirmed for competence following the procedure for personnel change management? 224. Do existing staffs meet the minimum experience requirements for safe operation of the processes and equipment? 225. Are PSSR team members competent in conducing PSSRs?

25





Table B.1 (Continued) The whole category is not applicable Select

Emergency response

Irrelevant

Relevant

226. Have emergency shutdown buttons passed functional tests? 227. Are measures in response to trigger of emergency shutdown systems presented in the emergency response plan? 228. Public utilities, such as water and electricity facilities, to be used in emergency responses, shall b e listed in the emergency response plan. If the availability of such utilities cannot be guaranteed, are there alternatives measures? 229. Have staffs received training on prevention from harm by release of toxic and hazardous materials? Are they verified to b e competent? 230. Have staffs received training on use of emergency shower and eyewash equipment? Are they verified to be competent? 231. Have staffs received training on use of positive pressure respirators? Are they verified to be competent? 232. Are emergency alarm devices provided? 233. Is emergency alarm devices reliable and easy to use? 234. Can emergency lighting systems work properly? 235. Are emergency escape routes and muster points clearly marked and known by all staffs? 236. Are escape routes unblocked and safe? 237. Are escape facilities (such as escape slide systems, ropes, etc.) prepared? 238. Are escape facilities reliable and easy to use? 239. Can the emergency response plan meet the requirements from process hazard analyses? 240. Have emergency response teams conducted relevant drills? 241. Are contacts for emergency rescue resources confirmed? 242. Are there backup contacts for emergency responses and can they meet safety requirements? 243. Are emergency rescue facilities equipped according to required quantity, type and location? 244. Have emergency rescue staffs received required training? Are they verified to be competent? 245. Are there adequate first aiders? 246. Have trainings on first aid procedures and methods been conducted and training results been verified? 247. Are first aid kits adequate? 248. Have emergency response communicated to all relevant parties?

plans

been

26

Deficiencies requiring actions Remaining Deficiencies requiring deficiencies prior correction





Environmental protection

Select Irrelevant


Relevant




249. Are characteristic descriptions of wastes documented and accessible? 250. Is there any information on environmental impacts of process materials? 251. Can discharge/emission control equipment work properly? 252. Are water drainages, sewage discharge facilities and cofferdams adequate to contain spills and polluted rainwater? 253. Can sewage pipeline drawings reflect actual changes? 254. Are isolating valves of water drainage closed? 255. Have waste (including commissioning wastes and defective products) treatment practices been determined? 256. Have environmental incident response procedures and resources (personnel, equipment, materials, etc.) been confirmed? 257. Can environmental laws, regulations and standards applicable in the host country and the environmental policies and procedures of the Company been complied with? The whole category is not applicable

PSSR checklists

Select Irrelevant


258. Does the checklist cover all safety inspection items required by the safe start-up and operation of the processes and equipment under review? 259. If not, the PSSR checklist should be discussed and improved by the PSSR team.

27






Appendix C PSSR Checklist (applicable to safety review before spud-in) Table C PSSR Checklist (applicable to safety review before spud-in) Date Well No. Rig No. Rig Contractor Inspection team

LOCATION

SN

Item description

1

All equipment are spotted properly as per the rig lay out & required safe distances. Location entrance & exit clearly identified with signs. All hazard signs are posted on location. Proper trough to be provided behind brine/mud tanks for draining waste to waste pit. Hazardous and non- hazardous waste bins are p rovided Adequate size of waste pit with proper lining has been provided. Ensure Confined Space Permit is completed and implemented prior to all cellar entries. Cellar area should be monitored for explosive gases/LEL, H2S & O2 levels with a Sniffer. Clean cellar, weld 4 dump valves on 42 conductor & check cellar jet pump is working okay. Ensure previous location is cleaned & leveled.

2 3 4 5 6 7

8 9

Y/N


AIR WINCHES SN

1

Item description

Y/N

Check condition of and function where relevant: a) Mountings b) Marking plates indicating up and down c) Marking plates indicating the SWL d) Wire line drum guards. e) Winch operating controls f) Winch safety controls

2 3

Ensure man riding tuggers are clearly designated. Check when mounting bolts last inspected or replaced.

28



4


Check air silencers.

BOP HANDLING SN

Item description

1 2

Check all functions are clearly labeled. Check when the overhead BOP cranes were last inspected and that they are currently certified. Ensure that cranes are free from obstruction over their full range of movement in the cellar pit area Check operation of all visual and audio warning devices fitted to BOP cranes.

3 4

Y/N


Y/N


Y/N


Y/N


BULK MUD AND CEMENT SYSTEM SN

1 2 3 4 5 6 7

Item description Make sure all the lines are correctly labeled. Make sure all silos are clean and dry. Pressure test all valves and lines up to the rated working pressure. Check certification of pressure relief valves. Ensure that valves vent into areas clear of personnel. Function test the vent lines, purge lines, supply and discharge lines. Check operation of bulk air compressors and driers Check condition of and function bulk mud hoppers and mixers.

CRANES & FORKLIFT SN

Item description

1 2

Check all crane functions are clearly labeled. Check PM records to ensure that there are no outstanding maintenance items and crane and associated equipment are fully certified. Operate crane and check that all functions and safety devices are operational. Check operation of all visual and audio warning devices fitted to crane and forklift. Check general condition of crane cabins, walkways and access ladders and stairs.

3 4 5 6

Check cranes and refueling systems for leaks.

DERRICK MAST SN

Item description

1

Check that the ladders and resting platforms are properly fastened and in accordance with the regulations.

29


2 3 4


Check operation and condition of climbing aids and derrickman's escape system. Check that all tools and equipment are safely stored or tied off. Rotary table centering with respect to mast + top drive & rotary center & cellar center

5 6 7

With cellar conductor pipe

8 9

Function test and check safe installation. Ensure that all shackles, blocks, slings etc. installed in the mast are correctly color coded and included in the lifting register. All shackle pins must be "wired". Check daily and weekly derrick checklists are in place and completed as required. Check that a "derrick management" system is in place regarding dropped object avoidance.

10 11

Check that lighting is adequate. Check equipment installed in the mast e.g. taggers, communications.

DOWNHOLE DRILLING EQUIPMENT SN

Item description

1 2

Drill Pipe last inspection. Visually examine all rig drill pipe, drill pipe pup joints and heavyweight drill pipe. Check general condition, correct grade and weight and date of last inspection. Check all pipes specified by contract are at the rig site.

3

Drill Collars:

Y/N


Y/N


Visually examine all drill collars and pup collars.

4

5 6 7

Checks as detailed above for drill pipe. Check to ensure that all other downhole tools (e.g. crossovers, bit subs etc) listed on the rig inventory are at the rig site and have been inspected as per contract. Check inventory and condition of drill pipe float valves and spares. BHA completely pick up & rack in derrick before spud BHA & drill pipes inspected. Submit copy of inspection report & BHA tally as listed on the rig inventory are at the rig site and have been inspected as per contract.

DRAW WORKS SN

Item description

1 2

Function test all controls. Run the travelling block up and down and check operation of:

30



a) Crown-o-matic b) Crown block saver c) Elmagco braking system

3 4 5

d) Emergency back-up system Check maintenance records with particular reference to break band replacement, NDT of critical components. Draw works cooling system OK. Check system for leaks.

DRILLERS CONSOLE & DOGHOUSE SN

1 2

Item description Check pressure gauges for correlation with other gauges a) Mud pressure

Y/N condition

and

b) Air pressure c) Water cooling

3

d) Oil pressure (draw-works) Check operation of all drilling instrumentation and whenever possible correlate readings e.g. check pit volume totalizer when leak testing mud pits. a) Top drive and rotary RPMs b) Flo-Show c) Pit volume totalizer d) Tong torque indicator e) Top drive and rotary torque f) Drilling recorder g) Electro-flow system h) Electrical and mechanical trip tank level i) Weight indicator

4 5 6 7 8 9 10

Check that all TV systems are working. Check that all alarms are working correctly. Check operation of communications systems including the drillers to the derrickman. All driller instrumentation, SDI- gelograph in working condition & calibrated, all SDI panels in TP, CO-MAN & SR-CO-MAN connected & working. Check that all switches, buttons, etc. are labeled and are in good condition. Check that all electrical switching corresponds to the panel description. (test run all machinery under every possible assignment). Check that all electrical equipment (e.g. switches, motors, junction boxes, etc.) are explosion proof or purged.

31



11 12


Check that there are no obstructions and that walkways and escape routes are clear. Check general condition of console including doors and windows.

FISHING TOOLS SN

1 2 3

Item description

Y/N


Y/N


Physically check inventory of all fishing tools to confirm that it contains all tools listed in the contract. Ensure that tools and grapples are available to catch all of the Contractor's drill string and crossovers. Ensure that all fishing tools have been redressed and inspected since last usage.

HYDRAULIC POWER UNITS SN

1 2 3 4

Item description Note: These tests refer to the unit(s) needed to power equipment such as Iron roughneck, facilities on top drive, casing tongs & other hydraulic equipment Operation of hydraulic power units will be checked when testing the above equipment. Check operating and emergency shutdown controls. Check for leaks, and note general condition of equipment. Check that unit's zone rating is correct for area in which the unit is located.

LOW PRESSURE PIPING & VALVES SN

Item description

1

Check all lines are clearly labeled to indicate contents.

2

Circulate through all lines (e.g. transfer, treatment and mixing) with water and check for leakage or plugging.

Y/N


Y/N


MUD AGITATORS SN

1 2 3 4 5

Item description Start all agitators before filling up the tanks. All mud agitators in working condition in all tanks. Check for noise and vibration. Check general condition and security of agitators, mountings and paddles. Check system in place for locking out motors.

32



MUD DEGASSER, DESNADER, DESILTER SN

1 2 3

Item description Check PM's on abnormalities.

motors,

drive

belts,

etc.,

Y/N


Y/N


for

Visually check equipment, and note general condition. Function test equipment.

MUD GAS SEPARATOR SN

Item description

1

Check general condition of separator and associated lines and valves.

2 3 4

Check and note date of last pipe thickness inspection. Flush through system with water. Check condition of all instrumentation located on the separator or at a remote location viz., in the driller's console.

MUD MIXING, TRANSFER AND CHARGING PUMPS SN

Item description

1

Run each pump separately for fifteen minutes with water and check for leaks and operating pressure. Run pumps against closed valves and check operating pressure.

2 3

Y/N


Y/N


Check inventory of pump spares.

MUD PITS SN

1

Item description Check general condition of: a) Pits. b) Gratings and access ladders. c) Isolating, equalizing and dump valves.

2 3 4

Ensure pits are clearly labeled. Fill each pit with water and check for leaks between adjacent pits and through isolating, dump and equalizing valves. Pump through and check operation of all mud guns.

MUD PUMPS MANIFOLDS AND HIGH PRESSURE PIPING SN

Item description

Y/N

1

Check that all lines and valves are correctly labeled and all valves have operating handles.

33



2 3 4 5 6 7 8 9


Flush all lines with water and fill up manifold. Pressure test pump manifold to rated manifold working pressure. Check pressure gauges and recorders, calibrate or replace if necessary. Whenever possible cross reference all gauges reading the same pressure source. Circulating system tested with all mud pumps. Ensure that there are no threaded high pressure connections on the manifold. Mud pump relief lines fixed. Check mud pumps fluid end & dressed with liners for spudding. Note date of last pipe thickness check.

POWER AND SERVICES SN

Item description

1

Check condition of and function test the main power generation systems. Check condition of and function test the emergency generator. Function test all air compressors including the cold start compressor. Check that all required safety devices are installed, operational and certified. Ensure that all air receivers and safety relief valves are certified.

2 3 4 5 6 7 8

Y/N


Y/N


Y/N


Check engines cooling system. Fuel supply system should be leak proof. All engines must be in running condition. Check condition of and function test sewage treatment plant.

PLANNED MAINTENANCE SYSTEM SN

Item description

1

Ensure that the PM system complies with the Rig's Verification Scheme for safety critical components Carry out random checks on the PM system to ensure that the work listed on the PM Task Forms has actually been completed Ensure that no critical safety or operational maintenance tasks are still outstanding on the PM system.

2 3

RIG FLOOR STAND PIPE MANIFOLD SN

Item description

1

Check that all lines and valves are correctly labeled and all valves have hand wheels.

34


2 3 4 5 6 7 8 9


Flush all lines with water and fill up manifold. Pressure test manifold to rated manifold working pressure. Rig up EZY torque, cat heads, iron rough neck & tested. Rig up survey wire line unit & sheaves. Check geograph is working. Check all wire ropes-drill-line, winch line, tong-line, etc. Check pressure gauges and recorders, calibrate or replace if necessary. Whenever possible cross reference all gauges reading the same pressure source. Note date of last pipe thickness check.

ROTARY TABLE AND TRANSMISSION SN

Item description

1 2

Function test the rotary table.

3 4 5

Check torque gauge.

6 7

Check for oil leakage Check condition of rotary bushings and ensure that dimensional checks have been carried out under the PM system.

Y/N


Y/N


Y/N


Check RPM counter. Check for abnormal noise or vibration in all gears. Make sure all ratios (low and high speeds) can be easily engaged.

SHALE SHAKERS SN

1 2

Item description Check the general condition of each shaker. Run each shaker and check for: a) Abnormal noise and vibration. b) Oil leakage.

3 4 5 6

Check inventory of spare parts, e.g. motors. Check shaker screens on all shakers and ensure all shakers in working condition. Check inventory of shaker screens and ensure that it is suitable for the proposed drilling programme. Check condition of valves on the header system and the discharge chutes.

STABBING BOARD SN

Item description

1

Check for safe installation of the casing stabbing board.

35


2 3 4 5


Check it is securely mounted in derrick. Check air supply, stabbing board controls, and backup safety systems. Function stabbing board for full movement up, down, extend and retract. Check stabbing board is not fouled by any other items of rig equipment, tugger lines etc. Check stabbing board is correctly certified as a lifting appliance.

SWIVEL SN

Item description

1 2

Check for oil leakage

3 4

Check for abnormal noise or vibration. The above will be tested to rated working pressure at the same time as the top drive.

Y/N


Y/N


Y/N


Check when new wash pipe was last installed.

TOP DRIVE SN

1

Item description Run the top drive up and down and check: a) Guide rails b) Fouling of cables and hoses with derrick and fittings

2

During test, check: a) Functions properly labeled on control panel b) All indicators / gauges working c) All electric devices explosion proof d) Oil leakage e) Air leakage f) Indicator lights operational

3 4 5 6

Install the IBOP and saver sub using the pipe handler. Function test the remote operated IBOP (Kelly cock). Pressure test the IBOP(S) and top drive mud circulation components to rated working pressure. Using Rotary tong with tong pull line check calibration of the torque indicator for make-up and break-out torque.

TRIP TANK AND FILL UP PUMP SN

1 2 3

Item description Flush system through with water. Rig up hole fill up line & line to trip tank. Check manual and electronic trip tank level measuring

36


4


systems and check correlation between the two systems. Ensure that the mechanical level measuring system can be clearly seen from the driller's console.

ADDITIONAL CHECKS SN

1 2 3 4 5 6 7 8 9 10 11

Item description

Y/N


Y/N


All ladders fixed & hand rails provided. All crew available for all shifts as per contract. Mud pits and charts calibration by geoloyg/datalog. Kill sheet is prepared Mud preparation as required volume and density. Prepare HI-VIS mud 90+ for sweeps. Rig up recycle pump from waste pit to mud tanks. Check flow-line /all lines are clear of all cutting & mudcake. Install water line to water tanks from water wells & fill all tanks. Rig up suitable lighting around tig, cat walk & cementing silos. All cutting troughs & overflow pipes to be put from tanks to waste pits. Check availability of proper X-over safety valves on rig floor.

HEALTH, SAFETY & ENVIRONMENT SN

1 2 3 4 5 6 7 8 9 10 11 12

Item description Function test all detection and alarm systems including: Fire / H2S / Gas / Smoke detectors / Fire alarms and emergency alarms. Check condition of firefighting equipment and check PM system to ensure that all equipment is fully certified and maintained. Function test fire water pump. Windsocks condition to be checked, if worn out to be replaced. Inform HSE Dept., Fire Station of new location. Ensure Oil spill kit is in place. Fire extinguishers placed in designated places. Inspection date labeled on extinguishers. MSDS for all chemicals in place & personnel aware of the hazards. Chemical storage organized, hazard signage placed. Smoking zone identified. Vehicle parking area identified. HSE induction & H2S training is in place. Check breathing apparatus kept on derrick floor & should be ready for use.

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13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35


Hazardous zones classified. H2S & other hazardous sign boards placed. Check condition of safety belts, free fall device etc. Eye wash facility on rig floor & mud tanks hooked up function test same. Hold H2S & BOP drill to see crew readiness. Two mustering points clearly marked on the location. Anchor all high pressure lines. Ensure First Aid Kit & stretcher is available. Required PTW is being used. Communication system operational. Log Book available and properly entered. Personnel equipped with safety glasses on rig floor. Aviation light operational All rig signs leading to the rig from the main road are posted. Ensure drip pans during filling / refilling of fuels. Ensure all hand rails, steps, stair casing in right order. Check any slip/trip hazards. All rotating equipment guarded. Ambulance with basic trauma care facilities ready. Rig is equipped with clinic with required facilities & manned by qualified doctor / licensed medic, nurse. Pre-spud meeting held. Site Specific Emergency Response Plan is in place & exercise prior to spud planned and conducted. Risks associated with the simultaneous operations in and around the location are assessed and communicated to the concerned personnel.

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Appendix D PSSR Checklist (applicable to safety review before penetrating into oil and gas formations) Table D PSSR Checklist (applicable to safety review before penetrating into oil and gas formations) Important Notes: The checklist is based on the national standards or petroleum industry standards of the People’s Republic of China, which should by no means substitute for, supersede or limit the requirements under the legislation and standards applicable in the host country. In case of any discrepancy between them, the more strict requirements shall prevail.

Date Well No. Rig No. Rig Contractor Inspection team

Items for review

1.

2.

3. 4. 5.

6.

7.

8.

9.

Item Description

A complete system of management documents are in place, including a work permit system which is strictly followed. Blowout, H2S and explosion response plans are in place, Management emergency drills have been conducted regularly and records are made. documents and records Well control devices meet the requirements in the original design, and well control measures specific to critical wells, complicated wells and special wells have been implemented. Well control equipment are regularly inspected and maintained. Staffs wear proper PPE as required, hold valid well control certificates and strictly observe safety procedures, rules and specifications. Protective equipment, including H2S monitoring devices and positive pressure type respirators, are regularly inspected and calibrated, adequate to meet demands and remain intact and operational. Basic requirements Production installations and electric equipment have proper grounding. No naked fire is used at the site. Diesel engines are equipped with flame traps. Electric equipment is explosion proof. Fire control equipment are adequately equipped and in valid period. The safety distance between the wellhead and duty room, warehouse, testing and logging room, geology room, boiler room,

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10. BOP and casing head

11.

12.

13.

14.

15.

16.

17.

18.

19.


oil tank, power generator, water tank, power distribution room, remote control console and camp meet relevant requirements. The blowout preventer has complete connection bolts and is secured; fluid lines are properly sealed; manual locking rods are intact and the end at hand wheel is supported firmly; the direction for On and Off and the number of turns for fully open are labelled; working platforms are easy for operation; thermal protection is used on the base of the drilling rig in winter seasons.

Blowout preventing lines are connected by threads and standard flanges, and on site welding is forbidden. Pipes longer than 7m are firmly secured. Anti-freezing measures are taken in winter seasons. The pressure level of casing head is consistent with that of blowout preventer. Mud guards are correctly installed. BOP stack, spools and gate valves are clean and clear of mud. Choke manifolds, kill manifolds and relief lines are correctly Choke connected, have flexible switches and in correct operational state. manifolds, Pressure gauges are inspected regularly. Anti-freezing measures are kill taken in winter seasons. manifolds, At every 10 - 15m, cornering positions, and outlets, relief lines blowout shall be supported and fixed by cement foundations with anchor preventing bolts or ground anchors, or forecast foundations. Hanging portions lines and shall be supported firmly. relief lines Outlets of relief lines are fixed by double cement foundations. Lines laying at vehicle crossings are protected. Safe ignition means are available for main relief lines. The power for remote control console is directly from the main power room or power distribution room through a dedicated power BOP control line and controlled by an independents switch. Pressure of the system power accumulator, annular BOP and manifold meet the relevant requirements. Upper and lower kelly cocks are flexible and easy to use; blowout preventer column, cross-over joint and check valve of drill tool are equipped; their rated working pressure is no less than that of BOP. Liquid level monitoring and other devices

Inlet and outlet lines and exhaust line of the liquid-gas separator are connected by flanges and firmly secured. Exhaust line is 50m away from the well site and has reliable ignition devices. Inventory of drilling fluid weighting materials meets the design requirements for both quantity and performance. The d rilling fluid weighting unit works properly and the weighting material feed hopper is unblocked.

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HSE - 5.7 Procedure for Pre-startup Safety Review Management

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