Document Qny0JjnoyBGKk4ab482v9eqk

ABD00102216 VISTA CHEMICAL COMPANY - ABERDEEN PLANT PROCESS SAFETY MANAGEMENT MANUAL PART G: PRE-STARTUP SAFETY REVIEW (PSSR) APPROVED BY: LANT AGER DATE: 1.0 SCOPE This policy establishes a Pre-Startup Safety Review (PSSR) procedure for the Aberdeen PVC Plant. A PSSR will be conducted for all new facilities installed and on modifications to existing facilities. Modifications to existing facilities are considered "changes" and are also subject to the provisions of Management of Change (see Aberdeen Plant Management of Change Procedure). Implementation of this policy will fulfill the requirements of OSHA 29 CFR 1910.119, paragraph (i). 2.0 PURPOSE The purpose of this policy is to ensure that a thorough review of potential hazards has been conducted on new and modified facilities prior to introduction of chemicals into the process or start-up of equipment. The review also ensures documentation exists as required for other elements of OSHA Process Safety. 3.0 DEFINITIONS Facility - A process unit and its associated equipment. Modified Facility - A facility which has undergone modification which resulted in a change to the process safety information. PSSR - Pre-Startup Safety Review PSSR Team - A Team consisting of representatives from appropriate departments such as Safety, Operations, Process Engineering, Project Engineering, Maintenance, and others as needed which has been established to conduct the PSSR. PSSR TEAM LEADER - The PSSR Team Leader will be designated by the Department Head over the "project" or "change". The Team Leader is responsible for providing the necessary documentation for review in the PSSR and for submitting the results of the PSSR to management. DATE OF ISSUE: 8/05/92 1 ABD00102217 A VISTA CHEMICAL COMPANY - ABERDEEN PLANT PROCESS SAFETY MANAGEMENT MANUAL PART G: PRE-STARTUP SAFETY REVIEW (PSSR) The Project Engineer will normally be designated as PSSR Team Leader for "projects". 4.0 APPLICATION The PSSR policy applies to any new facilities or modifications to existing facilities. It applies to all chemical processes at the Aberdeen Plant (e.g. Compound is included). Modifications to existing facilities are "changes" and subject to the provisions of both Management of Change and PSSR. This includes both capital projects and work order changes. 5.0 PSSR TEAM 5.0.1 Prior to start-up, a PSSR Team shall be formed to conduct the PSSR. Representatives from Operations, Safety, Maintenance, and Engineering departments should be selected for participation on the PSSR Team as appropriate. The Team make-up should be appropriate for the size and complexity of the PSSR to be conducted. Initiators of the "change" or members of the PHA team for the "project" or "change" should be considered for participation on the PSSR Team. The Department Head over the "project" or "change" is responsible for defining which Departments need to be represented on the Team. The PSSR may be conducted by an individual on simple "projects" or "changes" with approval from the appropriate Department Head. 5.0. 2 A PSSR Team Leader shall be designated for each PSSR by the Department Head over the "project" or "change". On "projects", the Project Engineer will normally be the PSSR Team Leader. The PSSR Team Leader will be responsible for contacting appropriate Department Heads and requesting other members for the PSSR Team. The PSSR Team Leader is responsible for ensuring all documentation (e.g. construction check sheets, etc.) is in-place and ready for review by the PSSR Team. 5.0. 3 It is the responsibility of the PSSR Team to conduct the PSSR in accordance with this policy and present the PSSR results to the appropriate Department Superintendent. DATE OF ISSUE: 8/05/92 2 ABD00102218 A VISTA CHEMICAL COMPANY - ABERDEEN PLANT PROCESS SAFETY MANAGEMENT MANUAL PART G: PRE-STARTUP SAFETY REVIEW (PSSR) 6.0 PSSR PROCEDURE The documentation requirements listed in items 6.1 through 6.3 below apply to "projects11 only. The required documentation for the PSSR for "changes" is filling out Attachment "B", the "PSSR FOR CHANGES CHECKLIST". 6.1 CONSTRUCTION REVIEW The Team will review the construction check sheets to verify all work is complete. During construction and prior to the PSSR, the PSSR Team Leader will document the progress of the construction. Attachment "A" is a sample check sheet to aid in the documentation during construction. The PSSR Team Leader is responsible for adding to or deleting from the sheet as needed, so all critical information is provided to the PSSR Team. 6.2 PHYSICAL HAZARD REVIEW / The PSSR Team will identify physical hazards at the construction site. Physical hazards are items such as tripping hazards, sharp objects, head clearances, etc. Attachment "C" is a guideline to be used in this physical hazard review for "projects". The PSSR Team Leader is responsible for adding to or deleting from the list as necessary. 6.3 ADMINISTRATIVE CHECKLIST Attachment "D", the "Administrative Checklist", should be filled out to document the following for "projects": 6.3.1 OPERATING, MAINTENANCE AND EMERGENCY PROCEDURES The PSSR Team shall verify the following procedures are in . place prior to startup of the facility: 6.3.1.1 Operating procedures as required in Aberdeen Plant Operating Procedure Development Control Policy. the and 6.3.1.2 Maintenance procedures including both .. preventative and routine maintenance as appropriate for equipment in the facility. DATE OF ISSUE: 8/05/92 3 ABD00102219 VISTA CHEMICAL COMPANY - ABERDEEN PLANT PROCESS SAFETY MANAGEMENT MANUAL PART G: PRE-STARTUP SAFETY REVIEW (PSSR) 6.3.1.4 Emergency response procedures as applicable. 6.3.2 PROCESS HAZARDS ANALYSIS AND MANAGEMENT OF CHANGE The PSSR Team shall ensure that a Process Hazards Analysis (PHA) has been conducted and that all recommendations resulting from the PHA have been addressed. The Team shall also verify that the modifications have been made in accordance with Management of Change provisions. 6.3.3 TRAINING The team conducted facility. certifies received. shall verify that appropriate training has been for operations personnel associated with the Documentation of training shall be available which that operations personnel understood the training 6.4 PSSR CHECKLIST FOR CHANGES Attachment "B" is the "PSSR Checklist for Changes". The checklist shall be filled out for all "changes" as defined in the Aberdeen Plant Management of Change Procedure. This list encompasses the requirements listed in sections 6.1 through 6.3 above in an abbreviated format. 6.5 RECOMMENDATIONS After completion of the PSSR, a list of recommended actions shall be generated by the PSSR Team. The list of recommendations shall be generated for all PSSRs ("projects" and "changes"). Each recommendation will be classified as either "critical" (C) or "noncritical" (N) . All "critical" items must be corrected prior to start-up of the facility. 7.0 REPORTING A PSSR Report shall be submitted to the appropriate Department Superintendent for approval upon completion of the PSSR. The report shall be filled out for all PSSRs ("projects and "changes") and should document that a PSSR has been completed for the facility DATE OF ISSUE: 8/05/92 4 ABDOO102220 VISTA CHEMICAL COMPANY - ABERDEEN PLANT PROCESS SAFETY MANAGEMENT MANUAL PART G: PRE-STARTUP SAFETY REVIEW (PSSR) in accordance with this policy. The PSSR Team Leader has the responsibility for writing and issuing the report. The report should include the following information: 7.1 A list of recommendations. 7.2 Assignment of priority (either "C" or "N") for each recommendation. 7.3 A reference to the appropriate code, policy, etc. applicable) for each recommendation. (if 7.4 Assignment of individual responsibilities for each recommendation. 7.5 Target completion dates for each "C" item and scheduled completion dates for all "N" items. 7.6 Non-critical items may be accepted without correction with written approval from the appropriate Department Superintendent. The appropriate Department Superintendent and the Safety Director have the authority for approval of the PSSR report. Attachment "E" is an example PSSR Report form. 8.0 STARTUP AUTHORIZATION Prior to startup, a Startup Authorization Statement shall be prepared by the PSSR Team Leader which certifies that all critical items have been corrected. The Startup Authorization Statement shall be completed for all PSSRs ("projects'1 and "changes"). Approval for start-up will be authorized by the appropriate Department Superintendent. Attachment "F" is an example Startup Authorization Statement Form. 9.0 DOCUMENTATION The approved PSSR Report and Startup Authorization Statement shall be maintained in the PSM files for the life of the facility. The PSSR Team Leader is responsible for filing this report in the PSM Files. DATE OF ISSUE: 8/05/92 5 ABDOO102221 Pre-Startup Safety Review Attachment "A" Issue Date: 08/05/92 CONSTRUCTION CHECKLIST PROJECT TITLE:_______________________________________________ AFE #: WO#: PROJECT ENGINEER:__________________________________________ PROCESS ENGINEER:__________________________________________ TASK MASTER P&ID'S UPDATED: PROJECT ENGINEER PROCESS ENGINEER PIPING SYSTEMS: LINE NUMBER:___________ PRESSURE TEST PIPE: MEDIUM:___________________ @ FOR NO. X-RAYS REQ'D: (ATTACH RESULTS) PIPE FLUSHED/TREATED: TREATED WITH: ___________ DATE PERFORMED BY: UNDERGROUND PIPE JEEPED: # CATHODES INSTALLED: : INSULATING FLANGES INSTALLED: SERVICE TEST STEAM TRACING: MEDIUM: @ FOR VINYL UNIT ONLY: ANY BLEEDER INSTALLED ON A LINE OR VESSEL CONTAINING VCM WILL BE REPORTED TO THE ABERDEEN ENVIRONMENTAL COORDINATOR FOR NESHAPS LIST. NO. OF VALVES REPORTED: A/ DATE OF ISSUE: 8/05/92 6 ABDOO102222 A* Pre-Startup (' Safety Review Attachment "A" Issue Date: 08/05/92 ATMOSPHERIC AND PRESSURE VESSELS : EQUIPMENT DATE PERFORMED BY: EQUIPMENT NUMBER DESCRIPTION:______ SHOP VESSEL INSPECTION REQ'D: YES/NO/NA _____________ VESSEL DOCUMENTATION: (BY MANUF.) AVAILABLE FOR REVIEW IN EQUIPMENT FILES: CALCULATIONS WELDER QUALIFICATION VERIFIED CERTIFIED DWGS ASME FORM (U, R, OR A) X-RAYS PROVIDED PER CODE MTL DATA SHEETS LINING OR PAINT SPECIFICATIONS STRESS RELIEVING YES/NO/NA YES/NO YES/NO/NA YES/NO/NA YES/NO/NA YES/NO/NA YES/NO/NA YES/NO/NA ( IF NO TO ANY ABOVE, WHY? \ MARK ITEM TESTED: (EXCHANGER SHELL SIDE, PRESSURE TEST: MEDIUM: @ FOR VESSEL) ______ FLUSHED/TREATED: ______ (EXCHANGER TUBE PRESSURE TEST: MEDIUM: @ FOR SIDE, VESSEL JACKET) ______ VESSEL FLUSHED/TREATED: ___ v DATE OF ISSUE: 8/05/92 7 ABDOO102223 Pre-Startup Safety Review Attachment "A" Issue Date: 08/05/92 SAFETY SYSTEMS: RELIEF VALVE: EQUIPMENT NUMBER ____________________ RELIEF COLOR CODED FOR PM: 1992 (CIRCLE ONE USED) 1993 1994 1995 1996 (1997) (1998) (1999) (2000) (2001) SET PRESSURE GREEN YELLOW RED ORANGE BLUE DOCUMENTATION ON FILE-AVAILABLE FOR REVIEW IN EQUIPMENT FILE. RUPTURE DISC BURST PRESSURE: LOT NUMBER:___________________ UNIT PROTECTED ALARM SYSTEM TESTED: FIRE PROTECTION SYSTEM TESTED: TYPE: TEST DESCRIPTION: DATE PERFORMED BY: A APPROVALS AND WITNESSES: DATE OF ISSUE: 8/05/92 8 ABDOO102224 Pre-Startup Safety Review Attachment "A" Issue Date: 08/05/92 MECHANICAL EQUIPMENT: EQUIPMENT EQUIPMENT NUMBER: DESCRIPTION:_______ DATE PERFORMED BY: ALIGNMENT:___________ LUBRICATION USED: CORRECT ROTATION: SEAL FLUID USED: VIBRATION CHECK: BUILDING PRESSURIZATION CHECK: (ATTACH TEST WITH WITNESSES) OVERHEAD CRANE HOIST: ATTACH CERTIFICATION AND IDENTIFY FOR MONTHLY TESTING WITH TOOL ROOM MECHANIC. ATTACH COPY OF CERTIFICATION AND TOOL ROOM IDENTIFICATION NUMBER FOR FUTURE REFERENCE. YES/NO/NA CIVIL/STRUCTURAL: ATTACH REFERENCE FOR SOIL TESTS PERFORMED (FILED WITH CONTRACT SUPERVISOR) UNDERGROUND DRAWINGS UPDATED DESIGN OF CONCRETE/STEEL IN PROJECT FILE MONORAILS ARE TO BE ENTERED INTO VMS SYSTEM AND CALCULATIONS FILED IN DRAWING ROOM. YES/NO/NA YES/NO/NA YES/NO/NA YES/NO/NA BUILDINGS: DOORS AND WINDOWS HUNG TO AVOID PROJECTING INTO OR BLOCKING WALKWAYS OR EXITS ELEVATORS EQUIPPED WITH SHAFT-WAY DOOR INTERLOCKS YES/NO/NA AND CAR GATES CONTACTS ELECTRICAL: POSITIVE ELECTRICAL POWER DISCONNECTS INSTALLED AND CHECKED FOR LOCKOUT PURPOSES RED CONCRETE FOR UNDERGROUND ELECTRICAL ELECTRICAL CLASSIFICATION OF UNIT UNDER CONSTRUCTION MOTORS:________________________________________________________________ INSTRUMENTATION:__________________________________________________ OTHER:__________________ YES/NO/NA YES/NO/NA YES/NO/NA DATE OF ISSUE: 8/05/92 9 A ABDOO102225 A Pre-Startup Safety Review Attachment "A" Issue Date: 08/05/92 INSTRUMENTATION & ELECTRICAL: INSTRUMENTATION CALIBRATION, CHECK OUT AND OTHER ACTIVITIES THAT APPLY TO CONSTRUCTION, INSTALLATION AND PRE-START UP CHECKS WILL BE RECORDED ON THE LOOP DIAGRAM SHEET. STAMPS WILL BE AVAILABLE IN THE DESIGN DEPARTMENT SIGNALLING NECESSARY CHECKS. THE PARTY RESPONSIBLE FOR CONSTRUCTION WILL GENERATE THE LOOP DIAGRAM LIST. AFFECTED IN ANY WAY BY THE CHANGE. THE PSSR TEAM WILL VERIFY LOOP CHECK OUT SIGNATURES ON LOOP DRAWINGS FOR COMPLETENESS. ELECTRIC TRACING WILL BE CHECKED IN THE SAME MANNER PRIOR TO INSULATION. DRAWING NUMBERLOOP NUMBERGENERATORPSSR TEAM DATE OF ISSUE: 8/05/92 10 ABDOO102226 Pre-Startup Safety Review Attachment "B" Issue date: 8/05/92 PSSR CHECKLIST FOR CHANGES 1. Is the equipment installed properly? 2. Is the area of the change free of physical hazards (e.g. head clearance, sharp edges, etc.)? 3. Has a Process Hazard Analysis been performed and all identified hazards addressed? 4. Has a MOCA form been filled out and all the requirements of the MOCA met? 5. Are operating, maintenance, and emergency procedures in place? 6. Is operator training complete and documented for the change? YES/NO/NA YES/NO/NA YES/NO/NA YES/NO/NA YES/NO/NA YES/NO/NA ( DATE OF ISSUE: 8/05/92 11 ABDOO102227 Pre-Startup Safety Review Attachment "C" Issue date: 8/05/92 PHYSICAL HAZARD REVIEW SAMPLE GUIDELINE A. Project Documentation 1. Is construction document provided by Project Engineer (PSSR Team Leader) complete? 2. Do project P&ID's show actual construction (in arrangement and pipe specifications)? 3. DCS documentation complete? B. Project Site Location 1. Is there adequate access for emergency vehicles? 2. Can access roads be blocked by railroads or road congestion? C. Buildings and Structures 1. Are sufficient general exit and escape routes available? Are means of escape from roofs provided? 2. Is adequate lighting provided? 3. Is structural steel grounded? 4. Are structural steel bases grouted? 5. Grating fastened or welded down? 6. Toe Boards in place? Handrails per Vista standard? D. Operating Areas 1. Are equipment, steam, water, air, and electric outlets arranged to keep aisles and operating floor areas clear of hoses, and cables? 2. Utility station properly labeled? Correct utility hose connections? 3. Is ventilation furnished for hazardous fumes, vapors, dust, and excessive heat? DATE OF ISSUE: 8/05/92 1 ( Pre-Startup Safety Review ABDOO102228 Attachment "C" Issue date: 8/05/92 A PHYSICAL HAZARD REVIEW SAMPLE GUIDELINE (cont.) 4. Are pressure relief discharges routed properly? Is there a 1/4" drain hole for pipe discharges to atmosphere? 5. Do platforms provide adequate clearance for safe maintenance of equipment? Forklifts, jibs, etc. 6. Do ladders/steps meet Vista specification? 7. Are nozzles and manholes sized and located for safe clean out, maintenance operations, and emergency removal of people from vessels? 8. Is protection provided to protect against contact with hot surfaces? Is insulation completed properly with sharp edges trimmed, wires removed and metal strips in place? Does pipe insulation seam run on bottom of horizontal pipe? 9. Is head clearance adequate in walkway and working areas? i/ ^ 10. Is power driven equipment adequately guarded? 11. Are manually operated valves, switches, and other controls accessible to the operator from a safe location? 12. Pinch points of valve handle and pipe, handrail, structure or other? Do valve stems extend into walkway or work area? 13. Are vents and drains located so they discharge safely? 14. Are hoists equipped with safety hooks? 15. Are monorails labeled for maximum load and equipped with safety stops? 16. Are emergency showers and eye baths provided and functional? 17. Is hearing protection required? needed? Are additional signs DATE OF ISSUE: 8/05/92 2 ABDOO102229 Pre-Startup Safety Review Attachment "CM Issue date: 8/05/92 PHYSICAL HAZARD REVIEW SAMPLE GUIDELINE (COllt.) 18. Has a safe storage and dispensing location for flammable liquid drums been provided? 19. Are additional fire extinguishers marked? extinguishers needed? Are 20. Are additional SCBA's needed? Are SCBA's clearly marked? 21. Are there at least two exits from hazardous work? 22. Is there safe exit from manufacturing offices or laboratories? 23 . Are exits marked? 24. Can electrical equipment be locked out? 25. Is equipment grounded? 26. Conduit poured and sealed? conduits plugged? Junction boxes closed and 27 . Verify maximum allowable working pressure for vessels are not exceeded by relief valve/rupture disc set pressure. 28. Are start-up strainers in place? 29. Are brass identification tags on equipment? Do location tags match P&ID drawings? 30. Vinyl bleeders plugged and painted? 31. Does system have fire protection system in place? 32. Area drainage adequate? Proper curbing? hazards painted safety yellow? Tripping 33 . Do drains run to correct sewer (storm vs. process)? E. YARD 1. Are flammable liquid tank car and truck loading and unloading docks grounded? 2. Are safe means provided for access to work areas of tank cars and trucks? DATE OF ISSUE: 8/05/92 3 ABDOO102230 A) Pre-Startup Issue date: ( Safety Review Attachment "CM 8/05/92 PHYSICAL HAZARD REVIEW SAMPLE GUIDELINE (cont.) 3. Is protection against falling furnished for employees who work on tops of rail cars and trucks? 4. Is safe access provided to tops of storage tanks on which persons go for contents measurement and vent maintenance?. 5. Derail flags installed? Other safety devices in place? DATE OF ISSUE: 8/05/92 4 ABDOO102231 Pre-Startup Safety Review Attachment "D" Issue date: 8/05/92 ADMINISTRATIVE CHECKLIST 1. Have MOC provisions (MOCA Section B) been met? YES/NO/NA 2. Has a PHA been performed and all identified hazards addressed? YES/NO/NA 3. Are operating procedures updated and in-place? yes/no/na' 4. Are maintenance procedures updated and in-place? YES/NO/NA 5. Is operator training complete and documented? YES/NO/NA 6. Are emergency response procedures updated (as required) in-place? YES/NO/NA DATE OF ISSUE: 8/05/92 5 ABDOO102232 Pre-Startup Safety Review Attachment "E" Issue date: 8/05/92 PRE -STARTUP SAFETY REVIEW REPORT FACILITY ____ DATE ____ TEAM MEMBERS NO. RECOMMENDATION PRIORITY SCH. COMP. RESP REF. RECOMMENDED: (PSSR TEAM) APPROVAL: Department Supt. DATE OF ISSUE: 8/05/92 6 Safety Director ABDOO102233 Pre-Startup Safety Review Attachment MFM Issue date: 8/05/92 START-UP AUTHORIZATION FORM Pro j ect: ________________________________________________ Date: MOCA No. I certify that all "critical" items identified in the PreStartup Safety Review (attach list of PSSR items to this form) have been completed and the facility is ready for start-up: Recommended: _________________________ PSSR Team Leader Title Approved: Department Superintendent Title DATE OF ISSUE: 8/05/92 7