faridbensaeed
27th February 2013, 10:35 AM
An action is defined as critical if it is an “uncontained risk” which may delay commissioning / hydrocarbons in.
Non-critical actions still require closure, but are considered to be contained (i.e. due date is “in sight”).
16 September
Requirement
Required Action/Status
Cat
Critical?
Co
Resp. Person
Due Date
*
The Most Basic Requirements to enable introduction of hydrocarbons as per Dag Peiffer’s email summary on 10 September
*1
Tested and operational gas and fire detection system
This replaces the action B2.
Critical actions that UHDE and Sazeh need to follow up:
Retype the actions from Mr Dalgliesh (Fire and gas alarm panel vendor representative) to get a soft copy and track the actions in the daily commissioning meetings.
Get Drager out IMMEDIATELY to calibrate the hexane sensor that is faulty.
The vendor will only return the Iran once EVERY SINGLE reservation is complete, but we can actually start up with parts of the system not yet operational. Therefore finalise the details of the test method and commissioning WITHOUT the vendor presence (i.e. before his return)
A
CRIT
S
U
A
Sani
F Peterson
P Mennell
01 Oct
*2
Tested and operational fire fighting system
This replaces the action H3 (but do not let H4 slip either).
Critical actions that UHDE and Sazeh need to follow up:
Finalise the test method.
Resolve the issues around the foam panel.
A
CRIT
U
S
A
F Petersen
Sani
P Mennell
01 Oct
*3
Functional emergency equipment e.g. safety showers, eye wash
This replaces the action A22
Critical actions that UHDE and Sazeh need to follow up:
There is re-engineering work required on the suction line of the pump.
Site check still required.
A
CRIT
U
S
A
Felix Petersen
F Safavi
Denis Bester
01 Oct
*4
Complete disconnection and removal of all temporary electrical equipment
Critical actions that Sazeh needs to follow up:
Provide a plan for the removal of all temporary electrical equipment.
A
CRIT
S
F Safavi
22 Sep
*5
Implemented access control system
Critical actions that UHDE and ASPC need to follow up:
Finalise training and train the trainers.
Implement the system.
A
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
26 Sep
*6
Implemented permit system
Critical actions that ASPC needs to follow up:
Continue to iron out problems with cold work, hot work, and confined space entries with audits and memos.
Roll out the electrical racking out/in procedure.
A
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
Ongoing
*7
Well implemented EMS
Critical actions that ASPC needs to follow up:
Close off outstanding actions from previous emergency exercises.
Create a plant-based emergency management procedure to compliment the site-based procedure.
A
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
01 Oct
*8
Mechanisms for communicating safety information down the line
This is a necessary extra that P Mennell added. Critical actions that UHDE, SAZEH, and ASPC need to follow up:
Get toolbox talks and safety committees up and running. They will take their topics from the daily commissioning meetings.
Create mail distribution groups for production and maintenance (including for Firmco).
Fine-tune (augment?) the instruction book system in the control room.
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
01 Oct
*9
All deficiencies (those listed with photographs in the addendum to the original PSSR action list) resolved
This is a necessary extra that P Mennell added. We have not been tracking these, so M Saleh must forward a SOFT COPY of the lists to P Mennell for incorporation into the PSSR meetings.
Also incorporate section F (emergency management) actions into this list.
A
CRIT
U
A
M Saleh
P Mennell
A
Occupational Safety and Health / Operations
A15
Sharp edges, crushing and impact points in the plant made safe
Inspection Report issued and accepted.
A
S
Salmanzadeh
Closed
A19
Escape routes marked, doors not blocked or locked
Sazeh to issue drawings to show where the escape routes are, and finalise the installation of the signboards.
Escape / emergency exit doors to be properly marked off on the outside.
A
S
Salmanzadeh
18 Sep
A20
Gathering (Muster) points marked
ASPC to finalise the design for the symbol and install at selected muster points.
A
A
A
J Adams
A Naeimi
Closed
A21
Signs in the plant
Contract says Sazeh installs only escape and fire system signs (addressed in A19).
ASPC must decide what other signs it wants (PPE, Hazardous materials) and install them.
A
CRIT
A
H Karimi
A Naeimi
01 Oct
A22
Emergency showers in operation, eye showers in operation
Covered in “Most Basic Requirements” action *3
A
Link
See *3
A23
Building lighting in operation and sufficient
FINAL illumination report required for the following:
Buildings
Control room
Substation
Plant areas
Bagging line
ASPC issued a preliminary report some time ago for the plant areas, and lux levels were too low in some places.
Also, some of the lights around the recycle gas compressor are not flameproof so must be removed for start-up, and will probably lead to even worse lux levels.
Testing to be done on Wednesday 19 September 19h00, and a report to be issued for ALL 5 areas by the next meeting.
Note that action B8 (the same thing for emergency lighting) also must be done.
See B8 for emergency lighting.
A
CRIT
S
A
Sani
H Karimi, E Grobler
22 Sep
A24
Intercom tested and available
There are concerns that the intercom system does not work when used FROM the FIELD. ASPC checked all intercoms and reported that the problems are limited to:
1501 and 1502 at homogenization (faulty general call)
1506 at 2nd flor extrusion (switch/knob broken)
Also, ASPC wants to have the numbers for calling from one field unit to another field unit(?).
Sazeh to fix the deficiencies.
This has been considered to be related to two-way radios, which are being dealt with separately.
A
A
S
Naeimi
Safavi
18 Sep
A27
General condition, house keeping
The general situation must be improved. Especially in the ex-zones all flammable materials and also all materials which could lead to an ignition must be removed. The entire polymerization steel structure (including below the installed gratings) must be cleaned.
A
S
A
Salmanzadeh
Denis Bester
15 Sep
B
Process Safety
B2
Gas warning system tested and in operation / Panel available
Covered in “Most Basic Requirements” action *1
A
Link
See *1
B8
Emergency lighting available and checked, including in control rooms and power stations
Sazeh has to submit inspection reports. Requirements:
Issue drawings to show locations of all emergency lights. These should be in all the same locations as for normal lights, that is:
Buildings
Control room
Substation
Plant areas
Bagging line
Identify all emergency lighting with appropriate symbols.
Carry out a live test of the diesel generator by switching all the incoming power off and see if the emergency lights come on, and check at the same time that the correct lights come one (the marked ones). Sazeh must do this since they are doing the switching. Do the test at 18h00 to see if the switching works, and leave on until 19h00 to do the lux meter readings. The test method to be approved by ASPC.
See A23 for non-emergency lighting.
A
CRIT
S
A
Sani / Khosravi
Grobler
01 Oct
B14
Pumps checked
Mechanical seal monitor in operation
Pump documentation available
This is an MC book issue.
Will be done system wise. Inspection reports have to be checked prior RFC. Re-categorized to A. Part of the MC-books.
A
MC Issue
B17
Fans and blowers tested and marked
Safety related exhaust fans and special requirements:
Analyser house air intake ducting, analyser, alarm, and interlock system to be checked.
Manual isolation on the fresh air supply to the control room HVAC also to be checked. What about analysers on this intake?
Blower hold by dummy run (C-80002) that hold by EP for relay.
Report to be issued stating where else these special fans, blower, and exhaust fan installations / control systems exist.
Some comments from previous meetings:
Inspection reports have been not available. A system must be set up to ensure that all fans and blowers have been tested prior RFC. All process blowers (radial and axial) must be handled in the same manner like pumps.
A
CRIT
S
A
U
Safavi / Sani will meet on 15 Sep
Naeimi / Mennell
M Saleh
22 Sep
B22
Level gauges/inspection glasses on vessels checked
Inspection report required to prove that all gauges and inspection glasses have been tested prior RFC. Is this really being checked by UHDE during final P&ID checks.
A
MC Issue
B24
Hydraulic (unit) equipment and pipes
Comments so far:
A visual check regarding leakage’s or spills has to be carried out on a frequently basis on site.
(Extruder) Vendor required.
B
MC Issue
D
Electrical Engineering, Instrumentation and Control (EEIC)
Note: IPF stands for instrument protective functions and denotes an instrument that inherently limits the protection system requirements (e.g. a control valve trim that limits the sizing requirement for a PSV). Such an instrument, including its constituents, may not be changed without taking due care to ensure the protection system remains adequate.
D8
Tech. data sheets for IPF / safeguarding facilities available
Operating manual, drawings and as-built docs to be made available in the control room, including for interlock and shutdown logic narratives.
U, S, A to meet on Monday 17 Sep at 15h00 to resolve this.
A
CRIT
S
A
?
Ashoordehi
17 Sep
D9
Alarm and Trip set points tested, IPF devices specially labeled
Alarm and trip points:
Checked within loop check.
As agreed between UHDE/Sazeh the interlock check will be done during commissioning.
Physically test must be carried out, only wiring was tested yet.
IPF devices (control valves, orifices, sensors, and actuators), data sheets, and logic specially labeled:
P&ID’s already indicate IPF devices.
Logic has been said to be done. Who said so?
Data sheets to be marked up.
Devices in the field to be specially tagged. ASPC to design a label and install on the IPF instruments.
If necessary, consider waiting till after start-up with the IPF labeling and use the MOC procedure as protection mechanism to prevent illegal changes to IPF-instruments. Peter Mennell to enter discussions with Dag Peiffer.
Checklists for regular checks must be created. This is present in the final documentation.
B
CRIT
U
S
A
?
?
?
30 Sep
D11
Sensors correctly adjusted or calibrated and labeled
Generally OK, since labeling, checking, and test is done as part of the loop check. Gas detection sensors are considered in action B2 above.
A
Link
See B2
D14
Control valves set, run and marked.
• "Fail-safe action" checked
• Seat and plug checked as per data sheet
As part of the loop check done. Does this really include the trim?
A
MC Issue
D15
Heating systems checked and in operation, safety temperature limiter switch correctly adjusted and checked
Sazeh to issue inspection report:
Heat tracing for capillary pressure transmitters.
Heat tracing for analyser lines.
This requires heaters to be energised, and must be done before system commissioning
A
MC Issue
D16
Quality certificates available
EX and quality certificates to be checked and confirmed:
Offshore confirmed by UHDE
Onshore also has been confirmed (incl. for HV cables).
The electrical junction box outside the analyser house does not meet the standard, and will not be accepted by ASPC. A replacement must be ordered. Check for others.
A
CRIT
U
S
A
Mohammed Saleh
Sani
Eben Grobler
15 Sep
D17
Power supply to all safety-related facilities checked for Battery back-up and Power inverters
To close this off, clarify which UPS units are where and what the requirements are for each. This requires Sani and Eben Grobler to get together BEFORE the next PSSR meeting:
DCS unit UPS:
To shut down the DCS
Fire alarm panel UPS:
This UPS has not been accepted by ASPC since
The UPS must move to the battery room with exhaust fans, and
The unit cannot be maintained since there is not enough space in the cabinet to access the wiring.
Also the battery back-up is no longer operable and must be replaced.
Other UPS:
???
A
CRIT
S
Sani
22 Sep
D18
Electrically driven motors – set point of over current trip correctly adjusted. Diagrams available, Displays in operation, Motors labeled
Motor trip set points:
Sazeh to bring the vendor for all 6.6 kV motors on 16 Sep. Peet le Grange to be present.
Vendors are not required for the 400 V motors. But the tests must be done for all motors, and especially a bump test must be carried out. Inspection report for motors with free run test available.
Main incomer trip set points:
Peet le Grange to supply survey findings for main incomers to Sazeh. Sazeh to fix shortcomings.
A
CRIT
S
A
Sani
Peet le Grange / E Grobler
16 Sep
D19
Motor valves run and set; marked
The motor valve on the extruder must be run and checked by the vendor, JSW.
Awaiting vendor presence.
A
S
?
?
D20
Lighting and emergency lighting of entire plant tested
Link
See B8
D21
All motors and actuators checked for cut-off criteria and marked
Only software-check done. Especially for IPF-functions (e.g. ESD) mandatory.
No marks found. (during Commissioning)
Pending (no clear statement from Sazeh)
Commissioning UHDE.
Also prepare to do a full on mock switching of the main ESD buttons. Do for ESD to see that the ESD switched work. Before hydrocarbons.
A
S
?
Commissioning
D22
All electrical equipment (distributors etc.) provided with warning signs, marked and secured against being touched
Minimum requirement from Sazeh:
Push buttons on (all) local panels are to be labeled with tags AS WELL AS descriptive text.
B
S
Sani
01 Oct
D23
Sockets checked and marked
Minimum requirement from Sazeh:
Installation report, punches, damages, function of safety switch.
Labeling to be completed.
Uhde to carry out a cross check for RCDs/sockets.
This is being done, and lists are up and running?
A
U
S
?
Sani
01 Oct
D24
Access to switch room, rack room clear
All switch room/rack room doors not properly labeled. Label doors. Exit signs.
A
S
Sani
01 Oct
D26
Cables protected against fire
Cables of fire fighting system have to be checked to make sure they are all of same type.
Certificates have been checked in Tehran office.
B
S
Sani
22 Sep
D27
Valves with handles: protected against accidental opening/ closing
B
Closed
E
Environment
E3
Plans of foundations and underground pipes available and "as built"
SAZEH to check and submit to Uhde documentation available.
B
S
?
MC issue
E6
Noise prevention observed; measurements conducted, specifications observed!
SAZEH engineering must submit documentation. A noise survey must be carried out during commissioning phase
B
S
Salmanzadeh
?
E10
Check for leaks of the ducts for waste water subject to treatment
Inspection Report to be checked. Separation rainwater should be checked by SAZEH. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
Refer to mc book building duct station
B
S
A
?
?
?
E11
Condition of the plant surfaces (joints, cracks)
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Shahani
?
E12
Retention possibilities for leaking liquids hazardous to water (oil separator, sewers, slop tanks etc.)
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Larizadeh, Salmanzadeh, Shehni
?
E13
Lining/coating of pump sumps and channels
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Mohamadi
?
?
E14
Collection of drips of substances hazardous to water from pumps/ Compressors etc.
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Larizadeh
?
?
G
Explosion Protection
G1
Explosion protection documentation available and up to date
Confirmed by ASPC
Only Ex-Zone plan available.
Uhde to check in SAZEH engineering documentation and to be cross checked by ASPC.
Link
See D16
G2
Hazardous zones are durable signed in pant
Sazeh still to install sign boards, yellow with black triangle and text “Ex”, on all entries of Ex-Zones in both polymerization and extrusion areas. Sazeh will provide drawings of the stands before installation.
Also install red line on ground around polymerization area (with distinct distance to building).
A
S
Salmanzadeh
01 Oct
G3
Lightning, earthing, bonding protection documentation is available and test is certified
Not checked during PSSR. Actually a short cut between instrument and electrical earthing was reported. Ongoing punch list.
A
S
Sani
MC Issue
G4
Arrangements against electrical charging are taken
No inspection reports available.
Not all flanges of powder transport/storage system are equipped with earthing strips.
A
S
Sani
22 Sep
G5
Certification for mechanical and electrical devices are available and manual is available in English language
Link
See D16
G6
Test certification for electrical installations is available according to local requirements
A
MC Issue
G7
Test certification for non electrical devices is available according to local requirements
Is this for anti-static shoes?
Refer to Peiffer / Jost to obtain clarity.
A
U
A
Saleh
Mennell
18 Sep
G8
Verification for intrinsically safe electrical circuits are available.
Document submitted to UHDE Germany by Mr Khajehzadeh. This calculation was not accepted. This must be resolved URGENTLY.
Copy of Ex-Certificates for electrical/instrument equipment should be added to loop check documentation and is recommended for every intrinsically circuit.
A
CRIT
S
U
Khajehzadeh
Schoeman
17 Sep
MC Issue
G9
Installation of „explosion protection by means of electrical devices is available, tested and documented
See Basell about this?
Link
U
M Saleh
18 Sep
G11
Protection systems correctly installed
G-111: Check required if power sockets in polymerization area are of the correct type. MC ISSUE
To be checked if locks have to be installed to avoid usage of non-intrinsically safe power sockets without permission. Not required.
G-112: Video-Boxes/installation not according to explosion protection. Electrical installation not according to regulations. Must be removed! Found at several places. CLOSED
G-113: Ex-i installation not correct.
To be checked for all sensors of same type. SCHOEMAN TO REPORT BACK
Being sorted out internally, as are all the other deficiencies.
A
U
Schoeman
22 Sep
G12
Maintenance-, test manuals, and test schedule, for protective systems (e.g. flame arrestors, rotor conveyors) available
ASPC asset integrity group to complete. This requires final documents, which ASPC mostly has.
B
?
A
Eben Grobler
30 Sep
G13
Primary protective systems according to explosion document are installed and tested (e.g. inerting system, air ventilation)
See Basell
This is an MC Book issue, and it requires that the installation is tested.
B
?
U
M Saleh
18 Sep
G14
Test documentation of primary protective systems available
See Basell
B
?
U
M Saleh
18 Sep
G15
Special, additional protective systems according to explosion document installed, tested and documented
see G-1. Not checked while explosion document not available.
Explanation by Basell
Is there anything over and above the analyser house? PM and NJ to check and then get the docs checked.
salmanzadeh
A
?
U
S
M Saleh
?
18 Sep
G16
Documentation of devices with special certification available
Available in vendor documentation. For offshore ok, for onshore to be checked by SAZEH
See Basell.
To be checked with SAZEH refer to sazeh final document
?
S
M Saleh
18 Sep
H
Fire Protection / Risk Prevention
H3
Spray water, deluge system, foaming system and/or other auxiliary systems installed and tested
Covered in “Most Basic Requirements” action *2
A
Link
See *2
H4
Extinguishers, fire blankets sufficiently in plant, control room, rack room, switch room available
This is an MC issue but Sazeh must issue an inspection report and confirm against the specified requirements. We do not currently have any fire blankets, but Sazeh claims that the extinguishers are on site (pressure indicators?).
Fire blankets are not in Sazeh scope, and must be supplied by ASPC.
Checklists of these critical items must be incorporated into the precomm checks.
A
CRIT
S
A
A
Salmanzadeh
Karimi
Mennell
22 Sep
01 Oct
30 Sep
H6
Fire protective insulation of constructions and vessels in place
Currently this is believed to be required only at the Poly extension structure. An inspection report for the coating was completed, and issued to UHDE. Uhde to confirm.
Sazeh engineering also to state where else fire resistance has been specified in the construction (besides the structure). ANSWER - There is nothing else.
refer to MC book poly, system 9003.
A
U
M Saleh
MC Issue
H7
Fire retarding sealing for piping and cable lead-through correctly installed
Final check pre commissioning to be done by Sazeh.
A
MC Issue
H8
Sufficient fire resistance of constructions for fire protection in place
Link
See H6
H9
Fire protective doors and flaps correctly installed
Sazeh to agree with UHDE what to do about the co-catalyst burn-off pit. The design is not considered satisfactory by Basell – follow up required.
A
S
F Safavi (speak to N Jost)
22 Sep
H10
Smoke and heat venation/hoods in place and in function
Sazeh to state where these are – THERE ARE NO HOODS - and submit an inspection report to Uhde prior RFSU.
A
S
Salmanzadeh
01 Oct
H11
Escape routes meet legal requirements
Site safety plan to be checked. ASPC and Sazeh will define the details. To check Engineering Documentation.
B
S
Salmanzadeh
?
H13
Water screen with gas warning facility in operation; CO2 flooding available
An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU.
To be clarified by Basell
B
S
Sani
?
Non-critical actions still require closure, but are considered to be contained (i.e. due date is “in sight”).
16 September
Requirement
Required Action/Status
Cat
Critical?
Co
Resp. Person
Due Date
*
The Most Basic Requirements to enable introduction of hydrocarbons as per Dag Peiffer’s email summary on 10 September
*1
Tested and operational gas and fire detection system
This replaces the action B2.
Critical actions that UHDE and Sazeh need to follow up:
Retype the actions from Mr Dalgliesh (Fire and gas alarm panel vendor representative) to get a soft copy and track the actions in the daily commissioning meetings.
Get Drager out IMMEDIATELY to calibrate the hexane sensor that is faulty.
The vendor will only return the Iran once EVERY SINGLE reservation is complete, but we can actually start up with parts of the system not yet operational. Therefore finalise the details of the test method and commissioning WITHOUT the vendor presence (i.e. before his return)
A
CRIT
S
U
A
Sani
F Peterson
P Mennell
01 Oct
*2
Tested and operational fire fighting system
This replaces the action H3 (but do not let H4 slip either).
Critical actions that UHDE and Sazeh need to follow up:
Finalise the test method.
Resolve the issues around the foam panel.
A
CRIT
U
S
A
F Petersen
Sani
P Mennell
01 Oct
*3
Functional emergency equipment e.g. safety showers, eye wash
This replaces the action A22
Critical actions that UHDE and Sazeh need to follow up:
There is re-engineering work required on the suction line of the pump.
Site check still required.
A
CRIT
U
S
A
Felix Petersen
F Safavi
Denis Bester
01 Oct
*4
Complete disconnection and removal of all temporary electrical equipment
Critical actions that Sazeh needs to follow up:
Provide a plan for the removal of all temporary electrical equipment.
A
CRIT
S
F Safavi
22 Sep
*5
Implemented access control system
Critical actions that UHDE and ASPC need to follow up:
Finalise training and train the trainers.
Implement the system.
A
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
26 Sep
*6
Implemented permit system
Critical actions that ASPC needs to follow up:
Continue to iron out problems with cold work, hot work, and confined space entries with audits and memos.
Roll out the electrical racking out/in procedure.
A
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
Ongoing
*7
Well implemented EMS
Critical actions that ASPC needs to follow up:
Close off outstanding actions from previous emergency exercises.
Create a plant-based emergency management procedure to compliment the site-based procedure.
A
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
01 Oct
*8
Mechanisms for communicating safety information down the line
This is a necessary extra that P Mennell added. Critical actions that UHDE, SAZEH, and ASPC need to follow up:
Get toolbox talks and safety committees up and running. They will take their topics from the daily commissioning meetings.
Create mail distribution groups for production and maintenance (including for Firmco).
Fine-tune (augment?) the instruction book system in the control room.
CRIT
U
S
A
M Saleh
F Safavi
P Mennell
01 Oct
*9
All deficiencies (those listed with photographs in the addendum to the original PSSR action list) resolved
This is a necessary extra that P Mennell added. We have not been tracking these, so M Saleh must forward a SOFT COPY of the lists to P Mennell for incorporation into the PSSR meetings.
Also incorporate section F (emergency management) actions into this list.
A
CRIT
U
A
M Saleh
P Mennell
A
Occupational Safety and Health / Operations
A15
Sharp edges, crushing and impact points in the plant made safe
Inspection Report issued and accepted.
A
S
Salmanzadeh
Closed
A19
Escape routes marked, doors not blocked or locked
Sazeh to issue drawings to show where the escape routes are, and finalise the installation of the signboards.
Escape / emergency exit doors to be properly marked off on the outside.
A
S
Salmanzadeh
18 Sep
A20
Gathering (Muster) points marked
ASPC to finalise the design for the symbol and install at selected muster points.
A
A
A
J Adams
A Naeimi
Closed
A21
Signs in the plant
Contract says Sazeh installs only escape and fire system signs (addressed in A19).
ASPC must decide what other signs it wants (PPE, Hazardous materials) and install them.
A
CRIT
A
H Karimi
A Naeimi
01 Oct
A22
Emergency showers in operation, eye showers in operation
Covered in “Most Basic Requirements” action *3
A
Link
See *3
A23
Building lighting in operation and sufficient
FINAL illumination report required for the following:
Buildings
Control room
Substation
Plant areas
Bagging line
ASPC issued a preliminary report some time ago for the plant areas, and lux levels were too low in some places.
Also, some of the lights around the recycle gas compressor are not flameproof so must be removed for start-up, and will probably lead to even worse lux levels.
Testing to be done on Wednesday 19 September 19h00, and a report to be issued for ALL 5 areas by the next meeting.
Note that action B8 (the same thing for emergency lighting) also must be done.
See B8 for emergency lighting.
A
CRIT
S
A
Sani
H Karimi, E Grobler
22 Sep
A24
Intercom tested and available
There are concerns that the intercom system does not work when used FROM the FIELD. ASPC checked all intercoms and reported that the problems are limited to:
1501 and 1502 at homogenization (faulty general call)
1506 at 2nd flor extrusion (switch/knob broken)
Also, ASPC wants to have the numbers for calling from one field unit to another field unit(?).
Sazeh to fix the deficiencies.
This has been considered to be related to two-way radios, which are being dealt with separately.
A
A
S
Naeimi
Safavi
18 Sep
A27
General condition, house keeping
The general situation must be improved. Especially in the ex-zones all flammable materials and also all materials which could lead to an ignition must be removed. The entire polymerization steel structure (including below the installed gratings) must be cleaned.
A
S
A
Salmanzadeh
Denis Bester
15 Sep
B
Process Safety
B2
Gas warning system tested and in operation / Panel available
Covered in “Most Basic Requirements” action *1
A
Link
See *1
B8
Emergency lighting available and checked, including in control rooms and power stations
Sazeh has to submit inspection reports. Requirements:
Issue drawings to show locations of all emergency lights. These should be in all the same locations as for normal lights, that is:
Buildings
Control room
Substation
Plant areas
Bagging line
Identify all emergency lighting with appropriate symbols.
Carry out a live test of the diesel generator by switching all the incoming power off and see if the emergency lights come on, and check at the same time that the correct lights come one (the marked ones). Sazeh must do this since they are doing the switching. Do the test at 18h00 to see if the switching works, and leave on until 19h00 to do the lux meter readings. The test method to be approved by ASPC.
See A23 for non-emergency lighting.
A
CRIT
S
A
Sani / Khosravi
Grobler
01 Oct
B14
Pumps checked
Mechanical seal monitor in operation
Pump documentation available
This is an MC book issue.
Will be done system wise. Inspection reports have to be checked prior RFC. Re-categorized to A. Part of the MC-books.
A
MC Issue
B17
Fans and blowers tested and marked
Safety related exhaust fans and special requirements:
Analyser house air intake ducting, analyser, alarm, and interlock system to be checked.
Manual isolation on the fresh air supply to the control room HVAC also to be checked. What about analysers on this intake?
Blower hold by dummy run (C-80002) that hold by EP for relay.
Report to be issued stating where else these special fans, blower, and exhaust fan installations / control systems exist.
Some comments from previous meetings:
Inspection reports have been not available. A system must be set up to ensure that all fans and blowers have been tested prior RFC. All process blowers (radial and axial) must be handled in the same manner like pumps.
A
CRIT
S
A
U
Safavi / Sani will meet on 15 Sep
Naeimi / Mennell
M Saleh
22 Sep
B22
Level gauges/inspection glasses on vessels checked
Inspection report required to prove that all gauges and inspection glasses have been tested prior RFC. Is this really being checked by UHDE during final P&ID checks.
A
MC Issue
B24
Hydraulic (unit) equipment and pipes
Comments so far:
A visual check regarding leakage’s or spills has to be carried out on a frequently basis on site.
(Extruder) Vendor required.
B
MC Issue
D
Electrical Engineering, Instrumentation and Control (EEIC)
Note: IPF stands for instrument protective functions and denotes an instrument that inherently limits the protection system requirements (e.g. a control valve trim that limits the sizing requirement for a PSV). Such an instrument, including its constituents, may not be changed without taking due care to ensure the protection system remains adequate.
D8
Tech. data sheets for IPF / safeguarding facilities available
Operating manual, drawings and as-built docs to be made available in the control room, including for interlock and shutdown logic narratives.
U, S, A to meet on Monday 17 Sep at 15h00 to resolve this.
A
CRIT
S
A
?
Ashoordehi
17 Sep
D9
Alarm and Trip set points tested, IPF devices specially labeled
Alarm and trip points:
Checked within loop check.
As agreed between UHDE/Sazeh the interlock check will be done during commissioning.
Physically test must be carried out, only wiring was tested yet.
IPF devices (control valves, orifices, sensors, and actuators), data sheets, and logic specially labeled:
P&ID’s already indicate IPF devices.
Logic has been said to be done. Who said so?
Data sheets to be marked up.
Devices in the field to be specially tagged. ASPC to design a label and install on the IPF instruments.
If necessary, consider waiting till after start-up with the IPF labeling and use the MOC procedure as protection mechanism to prevent illegal changes to IPF-instruments. Peter Mennell to enter discussions with Dag Peiffer.
Checklists for regular checks must be created. This is present in the final documentation.
B
CRIT
U
S
A
?
?
?
30 Sep
D11
Sensors correctly adjusted or calibrated and labeled
Generally OK, since labeling, checking, and test is done as part of the loop check. Gas detection sensors are considered in action B2 above.
A
Link
See B2
D14
Control valves set, run and marked.
• "Fail-safe action" checked
• Seat and plug checked as per data sheet
As part of the loop check done. Does this really include the trim?
A
MC Issue
D15
Heating systems checked and in operation, safety temperature limiter switch correctly adjusted and checked
Sazeh to issue inspection report:
Heat tracing for capillary pressure transmitters.
Heat tracing for analyser lines.
This requires heaters to be energised, and must be done before system commissioning
A
MC Issue
D16
Quality certificates available
EX and quality certificates to be checked and confirmed:
Offshore confirmed by UHDE
Onshore also has been confirmed (incl. for HV cables).
The electrical junction box outside the analyser house does not meet the standard, and will not be accepted by ASPC. A replacement must be ordered. Check for others.
A
CRIT
U
S
A
Mohammed Saleh
Sani
Eben Grobler
15 Sep
D17
Power supply to all safety-related facilities checked for Battery back-up and Power inverters
To close this off, clarify which UPS units are where and what the requirements are for each. This requires Sani and Eben Grobler to get together BEFORE the next PSSR meeting:
DCS unit UPS:
To shut down the DCS
Fire alarm panel UPS:
This UPS has not been accepted by ASPC since
The UPS must move to the battery room with exhaust fans, and
The unit cannot be maintained since there is not enough space in the cabinet to access the wiring.
Also the battery back-up is no longer operable and must be replaced.
Other UPS:
???
A
CRIT
S
Sani
22 Sep
D18
Electrically driven motors – set point of over current trip correctly adjusted. Diagrams available, Displays in operation, Motors labeled
Motor trip set points:
Sazeh to bring the vendor for all 6.6 kV motors on 16 Sep. Peet le Grange to be present.
Vendors are not required for the 400 V motors. But the tests must be done for all motors, and especially a bump test must be carried out. Inspection report for motors with free run test available.
Main incomer trip set points:
Peet le Grange to supply survey findings for main incomers to Sazeh. Sazeh to fix shortcomings.
A
CRIT
S
A
Sani
Peet le Grange / E Grobler
16 Sep
D19
Motor valves run and set; marked
The motor valve on the extruder must be run and checked by the vendor, JSW.
Awaiting vendor presence.
A
S
?
?
D20
Lighting and emergency lighting of entire plant tested
Link
See B8
D21
All motors and actuators checked for cut-off criteria and marked
Only software-check done. Especially for IPF-functions (e.g. ESD) mandatory.
No marks found. (during Commissioning)
Pending (no clear statement from Sazeh)
Commissioning UHDE.
Also prepare to do a full on mock switching of the main ESD buttons. Do for ESD to see that the ESD switched work. Before hydrocarbons.
A
S
?
Commissioning
D22
All electrical equipment (distributors etc.) provided with warning signs, marked and secured against being touched
Minimum requirement from Sazeh:
Push buttons on (all) local panels are to be labeled with tags AS WELL AS descriptive text.
B
S
Sani
01 Oct
D23
Sockets checked and marked
Minimum requirement from Sazeh:
Installation report, punches, damages, function of safety switch.
Labeling to be completed.
Uhde to carry out a cross check for RCDs/sockets.
This is being done, and lists are up and running?
A
U
S
?
Sani
01 Oct
D24
Access to switch room, rack room clear
All switch room/rack room doors not properly labeled. Label doors. Exit signs.
A
S
Sani
01 Oct
D26
Cables protected against fire
Cables of fire fighting system have to be checked to make sure they are all of same type.
Certificates have been checked in Tehran office.
B
S
Sani
22 Sep
D27
Valves with handles: protected against accidental opening/ closing
B
Closed
E
Environment
E3
Plans of foundations and underground pipes available and "as built"
SAZEH to check and submit to Uhde documentation available.
B
S
?
MC issue
E6
Noise prevention observed; measurements conducted, specifications observed!
SAZEH engineering must submit documentation. A noise survey must be carried out during commissioning phase
B
S
Salmanzadeh
?
E10
Check for leaks of the ducts for waste water subject to treatment
Inspection Report to be checked. Separation rainwater should be checked by SAZEH. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
Refer to mc book building duct station
B
S
A
?
?
?
E11
Condition of the plant surfaces (joints, cracks)
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Shahani
?
E12
Retention possibilities for leaking liquids hazardous to water (oil separator, sewers, slop tanks etc.)
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Larizadeh, Salmanzadeh, Shehni
?
E13
Lining/coating of pump sumps and channels
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Mohamadi
?
?
E14
Collection of drips of substances hazardous to water from pumps/ Compressors etc.
Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
B
S
A
Larizadeh
?
?
G
Explosion Protection
G1
Explosion protection documentation available and up to date
Confirmed by ASPC
Only Ex-Zone plan available.
Uhde to check in SAZEH engineering documentation and to be cross checked by ASPC.
Link
See D16
G2
Hazardous zones are durable signed in pant
Sazeh still to install sign boards, yellow with black triangle and text “Ex”, on all entries of Ex-Zones in both polymerization and extrusion areas. Sazeh will provide drawings of the stands before installation.
Also install red line on ground around polymerization area (with distinct distance to building).
A
S
Salmanzadeh
01 Oct
G3
Lightning, earthing, bonding protection documentation is available and test is certified
Not checked during PSSR. Actually a short cut between instrument and electrical earthing was reported. Ongoing punch list.
A
S
Sani
MC Issue
G4
Arrangements against electrical charging are taken
No inspection reports available.
Not all flanges of powder transport/storage system are equipped with earthing strips.
A
S
Sani
22 Sep
G5
Certification for mechanical and electrical devices are available and manual is available in English language
Link
See D16
G6
Test certification for electrical installations is available according to local requirements
A
MC Issue
G7
Test certification for non electrical devices is available according to local requirements
Is this for anti-static shoes?
Refer to Peiffer / Jost to obtain clarity.
A
U
A
Saleh
Mennell
18 Sep
G8
Verification for intrinsically safe electrical circuits are available.
Document submitted to UHDE Germany by Mr Khajehzadeh. This calculation was not accepted. This must be resolved URGENTLY.
Copy of Ex-Certificates for electrical/instrument equipment should be added to loop check documentation and is recommended for every intrinsically circuit.
A
CRIT
S
U
Khajehzadeh
Schoeman
17 Sep
MC Issue
G9
Installation of „explosion protection by means of electrical devices is available, tested and documented
See Basell about this?
Link
U
M Saleh
18 Sep
G11
Protection systems correctly installed
G-111: Check required if power sockets in polymerization area are of the correct type. MC ISSUE
To be checked if locks have to be installed to avoid usage of non-intrinsically safe power sockets without permission. Not required.
G-112: Video-Boxes/installation not according to explosion protection. Electrical installation not according to regulations. Must be removed! Found at several places. CLOSED
G-113: Ex-i installation not correct.
To be checked for all sensors of same type. SCHOEMAN TO REPORT BACK
Being sorted out internally, as are all the other deficiencies.
A
U
Schoeman
22 Sep
G12
Maintenance-, test manuals, and test schedule, for protective systems (e.g. flame arrestors, rotor conveyors) available
ASPC asset integrity group to complete. This requires final documents, which ASPC mostly has.
B
?
A
Eben Grobler
30 Sep
G13
Primary protective systems according to explosion document are installed and tested (e.g. inerting system, air ventilation)
See Basell
This is an MC Book issue, and it requires that the installation is tested.
B
?
U
M Saleh
18 Sep
G14
Test documentation of primary protective systems available
See Basell
B
?
U
M Saleh
18 Sep
G15
Special, additional protective systems according to explosion document installed, tested and documented
see G-1. Not checked while explosion document not available.
Explanation by Basell
Is there anything over and above the analyser house? PM and NJ to check and then get the docs checked.
salmanzadeh
A
?
U
S
M Saleh
?
18 Sep
G16
Documentation of devices with special certification available
Available in vendor documentation. For offshore ok, for onshore to be checked by SAZEH
See Basell.
To be checked with SAZEH refer to sazeh final document
?
S
M Saleh
18 Sep
H
Fire Protection / Risk Prevention
H3
Spray water, deluge system, foaming system and/or other auxiliary systems installed and tested
Covered in “Most Basic Requirements” action *2
A
Link
See *2
H4
Extinguishers, fire blankets sufficiently in plant, control room, rack room, switch room available
This is an MC issue but Sazeh must issue an inspection report and confirm against the specified requirements. We do not currently have any fire blankets, but Sazeh claims that the extinguishers are on site (pressure indicators?).
Fire blankets are not in Sazeh scope, and must be supplied by ASPC.
Checklists of these critical items must be incorporated into the precomm checks.
A
CRIT
S
A
A
Salmanzadeh
Karimi
Mennell
22 Sep
01 Oct
30 Sep
H6
Fire protective insulation of constructions and vessels in place
Currently this is believed to be required only at the Poly extension structure. An inspection report for the coating was completed, and issued to UHDE. Uhde to confirm.
Sazeh engineering also to state where else fire resistance has been specified in the construction (besides the structure). ANSWER - There is nothing else.
refer to MC book poly, system 9003.
A
U
M Saleh
MC Issue
H7
Fire retarding sealing for piping and cable lead-through correctly installed
Final check pre commissioning to be done by Sazeh.
A
MC Issue
H8
Sufficient fire resistance of constructions for fire protection in place
Link
See H6
H9
Fire protective doors and flaps correctly installed
Sazeh to agree with UHDE what to do about the co-catalyst burn-off pit. The design is not considered satisfactory by Basell – follow up required.
A
S
F Safavi (speak to N Jost)
22 Sep
H10
Smoke and heat venation/hoods in place and in function
Sazeh to state where these are – THERE ARE NO HOODS - and submit an inspection report to Uhde prior RFSU.
A
S
Salmanzadeh
01 Oct
H11
Escape routes meet legal requirements
Site safety plan to be checked. ASPC and Sazeh will define the details. To check Engineering Documentation.
B
S
Salmanzadeh
?
H13
Water screen with gas warning facility in operation; CO2 flooding available
An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU.
To be clarified by Basell
B
S
Sani
?