Document 3exg8LZXrk34V08EJGEdek6Mx
LOSS PREVENTION AUDIT Page 20
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Process Hazard Analysis
HAZOP
C 1. Do any of your unit operations have: Yes No [X] an F&EI of 128 higher? Yes [X] No a C.E.I. of 200 or higher or? Yes [X] No Q meet the criteria for conducting a HAZOP as outlined in the Process Risk Management Guidelines for Facilities and Distribution?
Plans: Plan to coordinate formalized HAZOP Review with Loss Prevention.
B 2. Where a HAZOP Review has been performed (please list areas studied), what is the status of the recommendations from the HAZOP study?
Process None
Process Unit
ADDITIONAL RISK EVALUATION
C 1. Yes 0 No [X] Has any additional risk evaluation or quantitative risk assessment been done in your facilities?
Plans: None
B 2. Yes [X] No Q Do you have a system for tracking risk evaluation recommendations until closed out?
Plans: Action item lists generated ('Pre-startup audits: action item and list of status') during pre-startup audits. MOC reviews, etc, are kept and audited until closed out bv project owner.
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(Revised 02/18/94; cmk) 3/28/95; LAD:bwb
DO A 0470SO
confidential
PLANT:
PRE-START UP AUDIT
C~Uor-<i !fc.//
____________
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PROJECT TITLE: ,Rtr d Ccn+n-fia * DATE:_. z/zfJJL
m4lcn
1. Has the Technology Center approved the process?
2. Has any reactive chemical data been generated?_
3. Has a reactive chemical review been done since the design was
finalized?
________ Attach the review letter along with a
written answei^ to any questions that were raised during the
p/'s`>
review. Has reactive chemical checklist been completed? N/A
4. Has Environmental Control reviewed and approved the project?
5. when the construction project is essentially complete, a job safety inspection should be made. This inspection should include:
Plant Supervisors Plant Engineer/Mfg. Rep-
Plant Operators Safety Department
Their inspection should enrohasize: Pipe, valves, fittings, and associated supports Valve location and orientation Structures and ladders Electrical grounding Insulation for personnel protection Safety showers Fire extinguishers and deluge guns Intercom locations Lighting Line labeling Freeze Protection PSV'S Instrumentation Has such a review been made?
6. Operator training classes should be held. These classes should highlight the following:
A. Project benefits and expected results.
B. Process description (include expected operating conditions)
Process controls
Operator responsibilities
New procedures: l. Start up 2. Emergency 3. Shutdown 4. Sampling S. job Procedure
7 . Lockout/Tagout 8. Loading/Unloading 9. Freeze Precaution
(normal/severe)
10. procedures:
6. Normal Operating Procedure
Has such training been done? \Jnrk.
SAFETY REFERENCE C-6 PRE-START OP AUDIT
'2
DO A 047051 CONFIDENTIAL
Procedures should be reviewed by as many plant people as possible
and revised as necessary. A plant committee of operations and
technical people should make a final safety audit of procedures
Has such a safety audit been done? fox j
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Has the system been pressure tested? ____
Washed or cleaned?
/?<?____________ How?
* 9-
Is it possible to have a dry run operation such as operating the
system on/^Tp5, nitrogen, or water?
____________ if so, has
this been oone? ZLh(*f 1*4____________ Are other plants involved in
the new process? n<->_____________________________________________'
=>r 10.
Have all instrument loops been checked and documented? /ytxf'-- r* 1
nF1u1 l1l range irvea*1 l*vrae Asf-twroaUkae)?
CF*ba1 i1l sa 9a'ffea tvraa1lvifeo rptrotosiifti1orntrtsc
verified?
Have critical instruments been
identified and registered?
fifru.
12.
Has the new electrical equipment been checked out? Are field 6^0/
switches, equipment and MCC starters labeled properly? Refer to
s-316 for electrical safety standards. &//<?/?*/
r^.
Have the block operating manual and emergency procedures been
modified to include the new project?
____________________________
13. Have pressure vessels and PSV's been added to the computer list? _______N/h____________ Do PSV's set pressure match design pressures
of vessels?
ni 4.____________________________________________________________
14. Have plant and engineering files and drawings (P&lD's) been updated to include the new equipment? <.J^s
15. Has a list of necessary spare parts been added to the existing spare parts stocking list? _________________________________________________
16. Have training classes been set up for maintenance of the new
equipment;
A-
17 . Has all associated equipment been checked?
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18. Has a review of the control system been completed? If computer control, has a simulation been done? __
This check sheet must be filled out and reviewed with the Plant Superintendent prior to the start up of a new project.
7
3/93
SAFETY REFERENCE C-6 PRE-START UP AUDIT
DO A 047050 CONFTDFNTTAl
Pg 3
PROJECT AND MODIFICATIONS SAFETY ASSESSMENT
PLANT 1
/T'ok- TITLE B>RP C&istRiFiy^fT /fet-GC/Wo*-'
Underline those factors which have been changed by Che proposal.
process acuDmoNs
ENGINEERING HARDWARE t, DESIGN
tenperature preaeure flew level composition toxicity flash point reaction conditions
OPERATING METHODS
routine operation shutdown going threxigh explosive
range preparation for maintenance abnormal operation emergency operation 1 yput Ti wrmiMnfiien r.f
controls & inct-rumenf
ENGINEERING METHODS
trip yiH 1n. taaMnrf maintenance procedures inspection portable equipment
SAFETY EQUIPMENT
m 5-(-`r7 u.JL**'
fire fighting fc detection systems
menu nf ^nr'"ra safety equipment for
personnel
growera c. BYManhBn
ENVIRONMENTAL CCNDITICNS
~r**L*>
liquid effluent solid effluent gaseous effluent* noise
SU
UTILITIES power, steam, nitrogen, water, air, fuel gas
line diagram
wiring diagram
electrical feeders distribution
plant layout
l~pr**U.
design pressure design tanperature
materials of construction
loads an, or strength of;
foundations
structures
vesBels pipework/supports/bellows
temporary or permanent: pipework/ supportB/bellcwe
valves slip-plates restriction plateB filters
instrumentation
^
tripe and alarms
static electricity - grounding
lightning protection
radioactivity rate of corrosion
rate of erosion
isolation for maintenance maintenance - electrical
fire protection of cables
haodcails ladders
<-- ,
platforms walkways
tripping hazards acoesB for:
m
operation nwinfwnantpe
vehicles
plant fire fighting
underground overhead: service
equipment safety relief devices
"normal freeze protection severe freeze protection
(30 deg. F, -10 deg. P
windehill)
%
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3/93
j
SAFETY REFERENCE C-6 PRE-START UP AUDIT
DO A 047053 CONFTDFNTTAt
Page 4
41
Within the aategerl.ee Hated below, does
*
RELIEF AMD RLOMDOMH 1. Introduce ar alter any potential cause of
over/under pressure (or raising or lowering tbs temperature in) the system or part of it? 2. Introduce a risk of creating a vacuum in Che system or part of it? 3. In any way affect equipment already installed far the purpose of preventing or minimizing over or under preesure? 4. Overloading of flare, blowdown or incinerator syetwn? AREA CLABBIFICATIOE 5. Introduce or alter the location of potential leaks of floanable material? 6. Altar the chemical composition or the phyaical properties of the process materiel?* 7. Introduce new or alter existing electrical equipment? SAFETT EQDXPMEMT 8. Require the provision of additional safety equipment?* 9. Affect existing safety equipment?* OPERATIOE AMS DEBIOR 10. Introduce new or alter existing hardware? 11. Require ccmeideraticn of the relevant Codes of Practice and Specifications? 12. Affect the process or equipment upstream or downstream of the change?* 13. Affect utilities at ocher plants in the Division? 14. Affect safe access for personnel and equipment, safe places or work and safe layout? 15. Require revision of equipment inspection frequencies? 16. Affect any existing trip or alarm protection? 17. Affect the reaction stability or controllability of the process?* 18. Affect existing operating or maintenance procedures or require new procedures? 19. Alter the composition of, or means of disposal of effluent 20. Alter noise level?* 21. Have Lose Prevention Principles been reviewed? 22. Is designed to operate through a normal freeze, not a severe freeze? *If y s, consider contact with Environmental Control, Reactive Chemicals, Safety and Loss Prevention, Industrial Hygiene groups or Engineering Services.
Yll
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X X X X X X
HO Whet problem has been areated whioh affect# pleat or personnel safety 4 whet eotion ie reooomeaded to minimise it?
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Checked by
Plant Superintendent Checked by Date
Engineer Date
3/93
SAFETY REFERENCE C-6 PRE-START OF AUDIT
Page 5
DO A 047054 CONFIDENTIAL
PRE-STARTUP AUDIT ATTENDANCE SHEET
PROJECT TITLE: L^C/T7c-t..
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AUDIT DATE:. STARTUP DATE:. ATTENDEES:
DEPARTMENT
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