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WW All S 04 010 Rev. 1, Dec 2010 PETRONAS CARIGALI PRE-ACTIVITY SAFETY REVIEW (PASR) GUIDELINE PETRONAS CARIGALI SDN BHD
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  • WW All S 04 010 Rev. 1, Dec 2010

    Philosophy of Lifesaving Appliances for Offshore Installations

    PETRONAS CARIGALI

    PRE-ACTIVITY SAFETY REVIEW

    (PASR) GUIDELINE

    PETRONAS CARIGALI SDN BHD

  • Pre-Activity Safety Review WW ALL S 04 010 Main Table of Contents Rev. 1, Dec 2010

    PETRONAS CARIGALI SDN BHD Main Table of Contents Page i

    PRE-ACTIVITY SAFETY REVIEW

    Main Table of Contents

    Preliminary

    Foreword

    Distribution List

    Amendment Summary

    Preface

    Glossary of Abbreviations and Acronyms

    Reference Documents

    Section 1 Introduction

    Section 2 PASR Process

    Section 3 Process-Related Activities

    Appendices Appendix 1 Sample of Samarang Process-Related Activity Procedures

    Appendix 2 Sample Checklist of Tembungo Integrated Shutdown Sequence

    Appendix 3 Sample of Checklist of Tembungo Integrated Startup Sequence

    Appendix 4 Sample of SMG-A Cooler Spading & Isolation List

    Appendix 5 Sample of TBG Integrated Plan on Paper (iPOP)

    Appendix 6 Sample of Pre-Shutdown Safety Review Checklist

    Appendix 7 Sample of Pre-Startup Safety Review Checklist

    Appendix 8 Full Pre-Startup Safety Review Checklist

    Appendix 9 Sample of Appointment Letter for PASR Team Leader

    Appendix 10 PASR Log

    Appendix 11 PASR Phase 2 Form

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    DISTRIBUTION LIST

    Copy No. Title Location

    01 CEO DPS MD-KL

    02

    02

    02

    CEO XS MD-KL

    03 XMAS XD - KL

    04 XSK XD - KL

    05 XSB XD - KL

    06 XPM XD - KL

    07 XINT XD - KL

    08 XAFR XD - KL

    09 XATL XD - KL

    10 XSEAN XD - KL

    11 XSEAS XD - KL

    12 XMEA XD - KL

    13 XTS XD - KL

    14 XGO XD - KL

    15 XBD XD - KL

    16 XPL XD - KL

    17 XHSE XD-KL

    18 DGM DD - KL

    19 DDR DD - KL

    20 DFE DD - KL

    21 DDW DD - KL

    22 DPP DD - KL

    23 DRMB DD - KL

    24 DDP DD - KL

    25 DHSE DD - KL

    26 FIN MD - KL

    27 CHSE MD - KL

    28 HRM MD - KL

    29 PED MD - KL

    30 RM MD- KL

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    31 SCM-CAA MD – KL

    32 SP MD – KL

    33 TIM MD – KL

    34 PI (CHO) MD – KL

    35 MO MO

    36 MO (HSE) MO

    37 VO VO

    38 VO (HSE) VO

    39 INO INO

    40 INO (HSE) INO

    41 MAU MAU

    42 MAU (HSE) MAU

    43 UO UO

    44 UO (HSE) UO

    45 PAK PAK

    46 PAK (HSE) PAK

    47 TO TO

    48 TO (HSE) TO

    49 IRQ IRQ

    50 IRQ (HSE) IRQ

    51 PM (CHO) MD-KL

    52 PMO PMO

    53 PMO (HSE) PMO

    54 SBO SBO

    55 SBO (HSE) SBO

    56 SKO SKO

    57 SKO (HSE) SKO

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    AMENDMENT SUMMARY

    This sheet must be completed in detail at each revision once this document has been

    approved.

    Details must include revision number, description and indication of which pages and

    paragraphs have been revised, date of revision approval, approvers title and signature.

    Rev Description Date Approver Title Signature

    1 Inclusion of PASR Phase 2 in Section 2 Dec 2010

    Notes:

    (1) Document Holders to update Amendment record as and when amendments/ new

    revision are received.

    (2) For description of amendment the Document Holder should indicate correction,

    modification, updates or deletion issue.

    (3) Document Holder to enter their company reference number, sign and date the

    record entry.

    (4) Where part amendments are issued, the relevant page(s) will be identified with a

    lower case letter in the revision line in the header.

  • Pre-Activity Safety Review WW ALL S 04 010 Preliminary Rev. 1, Dec 2010

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    PREFACE

    This Pre-Activity Safety Review (PASR) Guideline has been developed to ensure that all planned activities associated with process safety during drilling, facilities commissioning, production operations and maintenance, and facilities decommissioning are thoroughly reviewed prior to commencement to prevent adverse HSE consequences. The guideline is based on, or reference is made to relevant PETRONAS Technical Standards, and in line with PETRONAS Carigali’s HSEMS requirement. This document outlines the preparation requirement for process safety management to ensure the risks associated with the process have been reduced to ALARP level. This document only addresses process-related activities. It does not address the review requirement for non-process related activities. For non-process HSE critical activities, similar review/ risk assessment is required to ensure safe execution of activities. This manual shall be revised from time to time as required to ensure that any changes are documented and that any process safety related issues are correctly addressed. Any proposed amendment for continuous improvement from the users should be brought to the attention of Custodian by completing the standard revision request form. A copy of the standard revision request form is contained in PETRONAS Carigali Document Management Procedures (Document no. MY ALL A 05 002).

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    ABBREVIATIONS AND ACRONYMS

    The abbreviations and acronyms used in this document shall have the following meaning:

    ABV Actuated Ball Valve

    AGV Actuated Gate Valve

    ALARP As Low As Reasonably Practicable

    ASD Assembly Shutdown

    BC Battery Charger

    BDV Blowdown Valve

    CCR Central Control Room

    COTP Crude Oil Transfer Pump

    ESD Emergency Shutdown

    FTHP Flow Tubing Head Pressure

    GPA General Public Alarm

    HAZOP Hazards Operability

    HEMP Hazards and Effects Management Process

    HHP High High Pressure

    HP High Pressure

    HSE Health, Safety and Environment

    HSEMS Health, Safety and Environmental Management System

    ICR Instrument Control Room

    iPOCS Integrated Plant Operations Capabilities System

    JHA Job Hazard Assessment

    LCV Level Control Valve

    LIC Level Indicating Controller

    LOTO Lock-Out-Tag-Out

    LP Low Pressure

    LPS Low Pressure Switch

    LSL Level Switch Low

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    MCB Motor Circuit Breaker

    MOC Management of Change

    MOD Module

    MOL Main Oil Line

    NSD Non-Shutdown

    NTD Next Test Date

    OIM Offshore Installation Manager

    OPM Operations Procedure Manual

    OS Operation Supervisor

    PASR Pre-Activity Safety Review

    PCSB PETRONAS Carigali Sdn Bhd

    PCV Pressure Control Valve

    PETRONAS Petroleum Nasional

    PHA Process Hazard Assessment

    PL Pipeline

    PLC Programmable Logic Controller

    PM Preventive Maintenance

    PMCS Plant Monitoring Control System

    PPP Pipeline Protection Panel

    PRAP Process-Related Activity Procedures

    PSD Process Shutdown

    PSHL Pressure Switch High Low

    PSL Pressure Switch Low

    ROV Remote Operating Valve

    RV Relief Valve

    SCSSV Sub-Surface Safety Valve

    SD Shutdown

    SDS Shutdown Switch

    SITHP Shut In Tubing Head Pressure

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    SOS Senior Operation Supervisor

    SSV Surface Safety Valve

    TMM Topside Maintenance Management

    UPS Uninterrupted Power Supply

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    REFERENCE DOCUMENTS

    Doc. No. Title

    PTS 60.0101 Health, Safety & Environment Management System Manual

    PTS 60.0109 Production and Maintenance Guideline

    PTS 60.0401 Hazards and Effects Management Process (HEMP)

    PTS 60.2001 PETRONAS Group Guidelines for Permit to Work System

    PTS 60.2201 Management of Change (MOC)

    PTS 60.2203 Process Safety Information (PSI)

    PTS 60.2204 Process Hazard Analysis (PHA)

    PTS 60.2205 Operating Procedure (OP) Guideline

    PTS 60.2208 Pre-Activity Safety Review (PASR) Guideline

    WW ALL S 07 001 PCSB Health, Safety & Environment Management System Manual

  • Pre-Activity Safety Review WW ALL S 04 010 Introduction Rev. 1, Dec 2010

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    SECTION 1

    INTRODUCTION

    Contents Paragraph Page No.

    1 INTRODUCTION 2

    2 PURPOSE 2

    3 SCOPE 3

  • Pre-Activity Safety Review WW ALL S 04 010 Introduction Rev. 1, Dec 2010

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    1 INTRODUCTION

    This pre-activity safety review (PASR) guideline has been developed to provide guidelines to the PASR team, who are assigned by the facility owner to carry out safety review on the processes at the work site before commencement of planned process-related activities.

    All personnel who are involved in PASR must ensure that they are familiar with the requirements and procedures contained in this guideline.

    2 PURPOSE

    This guideline establishes requirements to conduct a safety review of processes to ensure safe implementation of planned activities. The risks associated with the planned activities shall be thoroughly assessed and the readiness shall be properly reviewed before the commencement of the activities, so as to produce its intended benefits without adverse side effects. The objectives of this guideline are:

    (1) Outline the requirements to carry out PASR.

    (2) Define selection criteria, roles and responsibilities of PASR team members, to ensure the effectiveness of safety review through proper assessment of process-related risks associated of planned activities.

    (3) Provide a coherent, systematic and as simple strategy as possible for all end users to ensure that all prior identified hazards and loss exposures associated with a planned activity’s implementation have been addressed to close-out before commencement of the planned activity.

    (4) Ensure the development of detailed activity procedure/ checklists for the process-related activities.

  • Pre-Activity Safety Review WW ALL S 04 010 Introduction Rev. 1, Dec 2010

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    3 SCOPE

    PASR is required for the following process safety related activities. It includes, but not limited to:

    (1) All process-related changes i.e. equipment change,

    operating parameter change, etc.

    (2) Pre-commissioning and commissioning of production facilities and equipment;

    (3) Planned shutdown of production facilities and equipment;

    (4) Start-up of production facilities;

    (5) Maintenance of equipment requiring process isolation;

    (6) Simultaneous production and drilling operations;

    (7) Simultaneous production and construction;

    (8) Simultaneous production and major maintenance; and

    (9) Decommissioning of production facilities and equipment.

    Details criteria for each of the process-related activities that require PASR is further elaborated in Section 3 of this document. This guideline will be reviewed when any of the following occurs, but not limited to:

    (1) Applicable regulations are introduced or revised.

    (2) Further improvement required.

    (3) Introduce new technology.

    All changes made in the PASR guideline shall be approved by the approving authority. The complete guideline shall be distributed to all relevant parties.

  • Pre-Activity Safety Review WW ALL S 04 010

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    Page 1

    SECTION 2

    PASR PROCESS

    Contents

    Paragraph Page No.

    1 PASR PROCESS FLOW 2

    1.1 PASR Process Overview 2

    1.2 Acceptance Criteria 7

    1.3 Roles and Responsibilities 8

    1.4 PASR Activities 9

    1.5 PASR Reporting and Documentation 10

    1.6 Outline of Process-Related Activities Procedure (PRAP) 11

    1.7 PASR Log 12

    1.8 Status Monitoring and Assurance 13

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    1 PASR PROCESS FLOW

    1.1 PASR Process Overview

    To ensure safe execution of the planned activities, PASR

    shall be conducted prior to the implementation of the

    activities. PASR is divided in two phases, i.e.

    (1) Phase 1: Risk assessment on the planned activities using the most appropriate tools e.g. HAZID, HAZOP, SWIFT, etc.

    (2) Phase 2: Review / verification exercise using appropriate checklist and / or procedures.

    Phase 1

    The hazards associated with the planned activities shall be

    assessed in accordance to the following guidelines:

    (1) Line manager (project manager, field manager, drilling manager) is responsible to identify the need for the conduct of PASR.

    (2) Line manager to appoint a competent team leader and team members.

    (3) Carry out PASR Phase 1 in accordance to this guideline. The review shall identify the required steps/ tasks in executing the process-related activity e.g. shutdown and/or start-up, as well as the required HSE controls to ensure risks associated with the process-related activities are ALARP.

    (4) Depending on the nature and complexity of the process-related activity, the appropriate type of tool must be chosen. Example of tools to be used for PASR Phase 1 may include: (a) HAZOP / Mini HAZOP

    (b) HAZID

    (c) Bowtie

    (d) Structured What-if Technique (SWIFT)

    (e) Customizes Checklist

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    (5) In addition, where process-related activities requiring

    the conduct of PASR Phase 1 is intended to be carried out simultaneously with another concurrent activities (e.g. concurrently with construction, maintenance, drilling, etc), the PASR Phase 1 assessment shall be extended to incorporate the risks attributed to the simultaneous activities. The sample assessment of concurrent maintenance activities for a planned shutdown is as illustrated in Appendix 5.

    (6) Recommendations resulted from PASR Phase 1 to strengthen the control and recovery barriers shall be incorporated in the relevant documents i.e. the associated procedures.

    (7) The deliverable of the PASR Phase 1 is a Process-Related Activity Procedures including checklists to ensure safe execution of the planned activity; for example Samarang-A Shutdown Procedures, Baronia-B Startup Procedures, Dulang-C Commissioning Procedures.

    (8) This Process-Related Activity Procedures shall become part of the documentation as required per PETRONAS Integrated Plant Operations Capabilities System’s (iPOCS) Turn Around Management Guideline.

    (9) Line manager to approve and implement the Process-Related Activity Procedure including relevant checklists, if any.

    (10) All related documents must be kept for 7 years as per HSEMS requirement by the line department.

    Phase 2 For ensuring all the identified control and recovery barriers are being implemented as well to confirm operational readiness to commence the planned activities, a review or verification exercise shall be conducted in accordance to the following guidelines: (1) Line manager to appoint a competent team leader

    and team members for the verification exercise.

    (2) Initiate PASR Phase 2 using PASR Form as shown in Appendix 11.

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    (3) In ensuring most of the relevant information has been

    deliberated and assessed, a checklist can be used to guide the team as well to record the findings. Sample checklist for shutdown and start-up are as illustrated in Appendix 6 and Appendix 7 respectively.

    (4) In addition, for new or modified facility-type review, the use of a standard commissioning checklist may usually suffice. The sample is as given in Appendix 8.

    (5) The planned process-related activity shall not proceed if the results from the verification exercise are not acceptable by the Management and/or the project team. Alternative or corrective actions shall be identified and the subject shall be reviewed again until satisfactory. However, some portions of the planned activities could probably commence upon Management’s endorsement.

    (6) Recommendations from the verification exercise shall be recorded and shall be closed prior commencement of the planned activities (subject to priority).

    (7) All related documents must be kept for 7 years as per HSEMS requirement by the line department.

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    Figure 2.1: PASR Phase 1 Process Flowchart

    No

    Yes

    Is the activity

    Process-related?

    Appoint PASR Team Leader and Members by

    line manager.

    Conduct PASR Phase 1 i.e. risk assessment

    for the planned activity

    Develop Process-Related Activity Procedures

    including checklists

    START

    Is it a HSE critical

    activity?

    No Proceed with the

    planned activity

    Conduct risk assessment

    review on the activity. *

    Is the Process-Related

    Activity Procedures

    approved by

    management?

    Yes

    No

    Proceed with the planned

    activity.

    Yes

    Implement all the required control and

    recovery measures to ensure safe

    execution of the planned activity

    * In line with the respective governing guideline.

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    Figure 2.2: PASR Phase 2 Process Flowchart

    START

    Proceed with the planned activity.

    Conduct PASR Phase 2 i.e. verification

    exercise using appropriate checklist

    Record PASR findings and follow up on

    results

    Are results from

    PASR Phase 2

    acceptable?

    * Conditions to close the findings/ commencing the activity shall be in line with item 1.2

    Appoint PASR Team Leader and Members

    by line manager.

    Do not proceed with the planned activity, identify

    alternative/ corrective actions and review again

    until satisfactory.

    Note: Some portions of the planned activities

    could probably commence upon Management’s

    endorsement.

    Yes

    No

    Close-out all findings from PASR

    Phase 2 exercise*

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    1.2 Acceptance Criteria

    Findings from PASR Phase 2 need to be prioritised based on the risk and practicality e.g. cost impact, prior execution of the planned process-related activities. For guidance in prioritising, PETRONAS Carigali Risk Assessment Matrix shall be used. The prioritisation of findings is essential in order to formally approve commencement of the process-related activity(ies), particularly in situations where PASR findings and action items are still outstanding. For situations where the planned process-related activity needs to commence prior closure of all the findings and action items, the execution shall be formally approved by appropriate level of authority based on the level of priority as outlined in the table below:

    Level of Priority

    Conditions to be met Approving Authority

    High Activity shall not be allowed to proceed until they are rectified

    -

    Medium

    Activity may proceed, subject to closure of findings/ action items within 2 weeks after commencement

    Field Manager

    Low

    Activity may proceed, subject to closure of findings/ action items within 1 month after commencement

    OIM

    1.3 Roles and Responsibilities

    Line Manager Line manager is the overall responsible person to organize, coordinate and execute the implementation of PASR in a safe and cost effective manner. The Line Manager shall also be responsible and accountable for the management and closure of all findings and actions items arising from PASR activities. PASR Team Leader PASR team leader is a competent operation personnel, who is appointed by Line Manager (e.g. Offshore Installation Manager). His duty is to carry out PASR

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    together with his team members prior to the execution of process-related activities. PASR members PASR team member is appointed by PASR team leader from among suitably competent personnel from various technical disciplines (e.g. operations, maintenance, reliability engineering, HSE, etc.) PASR Coordinator Each operating Region/ Division shall appoint PASR Coordinators to be responsible to administering PASR process. PASR Coordinator is a critical resource to ensure proper documentation of PASR activity, monitoring, adequacy of risk assessment and close-out documentation. These responsibilities are assigned to an individual within the functional group such as Field Engineer, and it is an addition to his/her normal duties. It is not separate position in the organization. The typical roles and responsibilities for PASR Coordinator as per followings: (1) Identify the process-related activities that require

    PASR.

    (2) Register the conduct of PASR in PASR Log.

    (3) Coordinate PASR sessions both Phase 1 and Phase 2

    (4) Maintain necessary information in PASR log, including tracking of action items and PASR closure.

    All PASR reports, for both Open and Closed PASR, shall be kept for a period of seven (7) years.

    1.4 PASR activities

    Process-related activities that are stated in item 1.2 (e.g. major start-up, shutdown, simultaneous operations, commissioning, decommissioning, etc), shall be subject to a Pre-Activity Safety Review (PASR), both Phase 1 and Phase 2. PASR team will conduct the safety review as per following activities:

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    Phase 1 (1) Identify the sequence of tasks required to execute the

    process-related activities (e.g. sequence of tasks to execute the plant shutdown/ startup).

    (2) Identify hazards associated with these tasks and identify the required HSE controls to ensure risks associated with the process-related activities are ALARP; and incorporate the identified controls in the sequence of task execution.

    (3) Document the sequence of tasks as well as the required HSE controls in Process-Related Activity Procedures including all relevant supporting documentation (e.g. risks assessment as carried out in item 2 above).

    (4) Where required, all relevant documentation shall be developed e.g. spading list, drawing, etc.

    (5) For guidance in developing the Process-Related Activity Procedures sample is attached.

    Phase 2 (1) Using an appropriate checklist suitable for the

    planned activity, a review or verification exercise shall be conducted in a team (note: the team could either be the same team of PASR Phase 1, or could be a different team).

    (2) The checklist shall be developed mainly to verify the implementation of the control and recovery barriers as well as the operational readiness prior commencing the planned activity.

    (3) The checklist shall be covering on below categories, but not limited to:

    (a) Work planning.

    (b) Isolations / normalisation of process lines.

    (c) Fire and gas detection and protection systems.

    (d) Utilities.

    (e) Logistics.

    (f) Equipment inspections and testing.

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    (g) Emergency response.

    (h) etc.

    The samples of checklist, depending on the type of planned activity, are as illustrated in Appendix 6, 7 and 8.

    (4) The checklists shall serve as a basis for the PASR Phase 2 team to customise their own checklist, taking categories as applicable to the needs of the planned activities, as well as to cover other activities which may not be directly related to the planned activities, but may still deserve to be part of the review scope as they may have the potential to cause adverse HSE effects to the facility.

    (5) As part of effective verification process, relevant documentations shall be referred to i.e. P&IDs, procedures, equipment inspection records, etc.

    (6) Interview with affected personnel and site check shall also be conducted to confirm the findings.

    1.5 PASR Reporting and Documentation

    The PASR and Process-Related Activity Procedures shall be reviewed by relevant technical authority and approved by line manager. All HSE controls identified in the Process-Related Activity Procedures shall be implemented prior to the commencement of the activity. The execution of the process-related activities is to be carried out in accordance to the approved Process-Related Activity Procedures. Any deviation shall be managed in accordance to MOC procedure including the requirement to assess risks posed by the change. The Process-Related Activity Procedures including checklists shall be kept for 7 years.

    1.6 Outline of Process-Related Activity Procedures (PRAP)

    The deliverable of PASR activities would be the Process-Related Activity Procedures (PRAP) and the outline shall cover detail information of the process related activity, the

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    affected facilities, the required steps/ tasks in executing the process-related activity as well as the assessment of simultaneous maintenance activities. However, the outline of PRAP depends on the type of process-related activity, and is not limited to the list specified below (sample outline below is for planned shutdown): (1) Title Page. (2) Authorisation Page. (3) Shutdown Work Program

    (a) Facilities affected during shutdown.

    (b) Platform status.

    (c) Operating Medium.

    (d) Floating Resources.

    (e) Alarms & Shutdown system.

    (f) Shutdown HSE Plan.

    (4) Shutdown Activities Workscope for each Facility.

    (5) Shutdown Procedure.

    (6) Flushing Procedure.

    (7) Integrated Plan on Paper (iPOP).

    (8) Leak Test and Purging Procedure.

    (9) Start-up Procedure.

    1.7 PASR Log In addition to Process-Related Activity Procedures (PRAP) and PASR Phase 2 report, PASR Coordinator for each Region and Division shall also maintain a master register of all PASRs initiated within PETRONAS Carigali Region and Division. This may be referred to as Pre-Activity Safety Review (PASR) Log. The PASR Log shall include, as a minimum for effective traceability, detailed information covering: (1) A coding or numbering system for each PASR.

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    (2) A name or title for each PASR; mainly indicating the process-related activity.

    (3) A date recording the initiation/ execution and completion of each PASR.

    (4) Notes or remarks to detail any changes to the initial logging of the PASR activity, status, etc.

    (5) Reference to other process e.g. MOC.

    Sample of PASR Log is as shown in Appendix 10.

    1.8 Status Monitoring and Assurance

    In order to help ensure that each Pre-Activity Safety Review system delivers its intended benefits suitably, adequately and effectively, an assurance system is established to serve as mechanisms and procedures to measure, monitor and provide assurance with respect to

    performance of PASR implementation. Assurance on PASR should be conducted as part of the overall HSEMS Assurance activity at the facility (as per PTS 60.0102 and PTS 60.0301).

    1.8.1 Status Monitoring

    The objective of monitoring PASR implementation is to ensure: (1) Findings and action items are properly evaluated and

    approved at appropriate levels.

    (2) Implementation and close out of PASR are documented by a review of required records: (a) PASR Logs.

    (b) Process-related Activity Procedure (PRAP).

    (c) PASR Phase 2 checklist.

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    1.8.2 Action Tracking

    A system shall be established to ensure that all action items are properly monitored and managed to completion. Action tracking as a minimum requires the establishment of a formal system and procedure for: (1) Tracking the status of, and following-up on, identified

    corrective and preventive action items arising from PASR activities

    (2) Tracking the status of, and following-up on, identified corrective and preventive action items arising from assurance activities and their respective assurance reports.

  • Pre-Activity Safety Review WW ALL S 04 010 Process-Related Activities Rev. 1, Dec 2010

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    Page 1

    SECTION 3

    PROCESS-RELATED ACTIVITIES

    Contents

    Paragraph Page No.

    1 PROCESS-RELATED ACTIVITIES 2

    1.1 Process-related Changes 2

    1.2 Planned shutdown 2

    1.3 Unplanned shutdown 3

    1.4 Startup situations 3

    1.5 Facilities purging 5

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    1 PROCESS-RELATED ACTIVITIES 1.1 Process-related Changes

    As part of the Management of Change (MOC), any process-related change shall be subjected to PASR. In complying with MOC system requirements, risk assessments shall be conducted for all change proposals, using an appropriate type of review tool depending on the nature and complexity of the change. Therefore this is in compliance with PASR Phase 1 requirements. PASR Phase 2 shall also be conducted prior execution of the activities and action items shall be tracked to closure as part of PASR Management.

    1.2 Planned shutdown

    PASR is deemed necessary for major shutdown that fulfils any of below criteria to ensure all the HSE controls are in place, and risks are minimized to ALARP prior to startup:

    (1) Shutdown duration is more than 24 hours.

    (2) Change of equipment, operating parameters,

    chemicals or anything that may affect the process or potential cause of loss of containment.

    (3) Mothballing i.e. hazards contained in any equipment.

    (4) Involving simultaneous operations i.e. SIPROD.

    For shutdowns that do not meet any of the criteria above i.e. unit shutdown (USD), PASR may not be required, provided that the activity does not pose high risk and it is safeguarded by an updated operating procedure. In carrying out the PASR, in particular the development of the Process-Related Activities Procedures for a planned shutdown, the following process-related safeguards are to be considered: (1) Empty sump pile, sump caisson and sump tank.

    (2) Perform vent line flushing, if applicable.

    (3) Reduce intake and export.

    (4) Close in flowing wells.

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    (5) Bring down liquid level of vessels, gas compressors

    separators to the lowest possible point.

    (6) Ramp down all export compressors until idling speed.

    (7) Start portable air compressor.

    (8) Trigger ESD or initiate shutdown.

    (9) Lock out GPA at CCR console.

    (10) Perform ESD checklist on all ABV and BDV position as per logic.

    (11) Isolation, depressurising, draining and water flushing the lines subject to maintenance or construction work including associated lines up to the first isolation points.

    (12) Locking and tagging of isolation valves or spades as per shutdown spading list.

    (13) Identify and install barriers for all live lines.

    (14) Proceed with shutdown work.

    1.3 Unplanned shutdown

    PASR is deemed necessary for any unplanned shutdown to ensure all the HSE controls are in place, and risks minimised to ALARP prior to startup. Process-Related Activity Procedures are required for any unplanned shutdown (PSD and ESD) and it can be developed beforehand. The cause of the unplanned shutdown shall be investigated and rectified prior startup.

    1.4 Startup situations PASR Phase 1 & 2 shall be conducted for 4 startup situations of offshore and onshore facilities, namely commissioning startup, startup after process shutdown (PSD), startup following emergency shutdown (ESD) with depressurisation, and startup following emergency shutdown (ESD) without depressurization. Additionally, PASR is deemed necessary for startup after shutdowns that fulfill any of the criteria as stated in item 3.2.

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    1.4.1 Startup following PSD or ESD (with or without depressurization)

    PASR Phase 1 & 2 shall be conducted and Process-Related Activity Procedures shall be developed for any startup following PSD or ESD (with or without depressurisation). The document shall be approved by the Offshore Installation Manager (OIM), with the cause of shutdown investigated and rectified. In certain circumstances, the required Process-Related Activity Procedures can be developed beforehand and incorporated into OPM.

    1.4.2 Commissioning startup

    Commissioning startup is associated with commissioning of new facilities.

    The following requirements among others shall be fulfilled prior to start-up.

    (1) All construction works shall be completed with appropriate handover certificates or reports signed off by the platform authority.

    (2) All pipework have been hydrotested and drained.

    (3) Ensure all positive isolations i.e. spades or blinds installed during the shutdown are removed.

    (4) The instrumentation has been calibrated.

    (5) All trips and relief valves are in the right setting as per start-up procedure.

    (6) Facilities are purged with inert gas to prevent the possible build up of an explosive mixture in the system.

    PASR Phase 1 & 2 shall be conducted and Process-Related Activity Procedures shall be developed and incorporate all the controls into Operating Procedures Manual (OPM) for the black startup of the facility.

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    1.5 Facilities purging

    Purging is important especially for commissioning startup and startup after major maintenance shutdown.

    Purging is required to remove the air (oxygen) presence inside the facilities which may possibly cause explosion. Purging shall start from the further upstream point, allowing the inert gas to sweep the air inside the facilities to the furthest possible downstream point. The following procedure should be used as a general guide for purging the facilities: (1) Open the purge connection preferably on the bottom

    of the vessel or upstream of the facilities and the valves on top of the vessel or downstream of the facilities preferably the manual depressurisation valves.

    (2) All the valves on the level gauges and level switches on vessels and any other instrumentation on vessels or facilities should be in open position during purging.

    (3) Close all the drain valves on all vessels.

    (4) Start injecting nitrogen into the system at the purge connection or upstream of the facilities. Nitrogen will displace the air in the vessel or facilities and the air together with nitrogen will be evacuated through the other end to the atmosphere or through the manual depressurisation line to the vent system.

    (5) Pressurised the system with nitrogen and depressurised slowly to desired pressure as per site-specific purging procedure.

    (6) Repeat the pressurisation and depressurisation cycle until the oxygen concentration in the system reduced to between 0% - 7%. Oxygen concentration shall be regularly checked at the purge outlet connection using portable oxygen analyzer.

    (7) After purging operation completed, facilities shall be prepared for start-up.

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    APPENDIX 1

    Contents

    Appendix Page No.

    1 Sample of Samarang Process-Related Activity Procedures A1-1

    2 Sample Checklist of Tembungo Integrated Shutdown

    Sequence

    A2-1

    3 Sample Checklist of Tembungo Integrated Startup

    Sequence

    A3-1

    4 Sample of SMG-A Cooler Spading & Isolation list A4-1

    5 Sample of TBG Integrated Plan on Paper (iPOP) A5-1

    6 Sample of Pre-Shutdown Safety Review Checklist A6-1

    7 Sample of Pre-Startup Safety Review Checklist A7-1

    8 Full Pre-Startup Safety Review Checklist A8-1

    9 Sample of Appointment Letter for PASR Team Leader A9-1

    10 PASR Log A10-1

    11 PASR Phase 2 Form A11-1

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    Appendix 1 Sample of Process-Related Activity Procedures

    SAMARANG INTERGRATED SHUT DOWN AND STARTUP PROCEDURE

    PLATFORM : SMG-A /SMP-A/SMDP-A /SMP-B/SMDP-B/ SMP-C /SMJT-D /SMJT-F /SMJT-G /SMJT-E/ SMR-A/ SMK-A

    PLAN START : 14-09-2004 to 20-09-2004 Duration : 5 days

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    AUTHORISATION This guideline contains the arrangements and precautions required for shut down and start up by the ASSET Custodians to ensure the safe execution of the Samarang TMM project, riser repair, pipe line repair, valves change out, hot work activities etc.(refer to the scope of work) By the contractors with work boat assistance. During shut down and start up operation, all activities will be stop for operation to do depressurize or pressurize the systems and make isolations. It also to reduce potential extended time for depressurizes pipeline or vessels. The objective is to ensure all focal point are clear of their function and responsibility and ultimately are able to respond to an emergency in their capabilities and capacity during the period. In the event if there is conflicting statement or uncertainties between this shut down and start up procedure with existing documents and any changes during the actual implementations, the matter is to be revert to the OIM, SOS, OS and operation in charge.

    Name Signature Date

    Prepared by Yousof Bin Ahmad (Operation Tech)

    Reviewed by Boneface Albanus (SOS-Samarang) M Anton Abdullah (SOS-Samarang)

    John Masudal (OS-Samarang) Fairuze Yahya (OS-Samarang)

    Endorsed by M Johari Amir (OIM-Samarang) A. Thamilrasu (OIM-Samarang)

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    TABLE OF CONTENTS Paragraph Page No

    1 Introduction 4

    2 Summary Scope of Work 5

    3 Shut Down Guideline For SMG-A 7

    4 Shut Down Guideline For SMP-A, SMJT-E & SMJT-G 8

    5 Shut Down Guideline For SMP-B 10

    6 Shut Down Guideline For SMP-C, SMJT-D & SMJT-F 11

    7 Shut Down Guideline For SMR-A 12

    8 JHA Attachment 13

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    1 INTRODUCTION 1.1. SIPCOM WORK PROGRAM

    1.2. Platform : -

    SM Central: SMQ-A, SMG-A, SMP-A, SMDP-A, SMJT-E, SMJT-G,SMV-AA, SMV-A & SMR-A SM Northern: SMP-B, SMDP-B SM Southern: SMP-C, SMJT-C, SMJT-D, SMJT-F Samarang Kecil

    1.3 Platform Status : Shut down/Live during pre and post shut down activities.

    1.4 Operating Medium: Instrument air (Central) & Instrument Gas.

    1.5 Floating Resources : Rental Work Boat ( MV Sirocco)

    1.6 Major Facilities : Facilities that will be maintained live during pre / post shut down job and total shut down during project.

    1.7 Alarm and Shutdown System : Platform alarm and shutdown systems are to be functionally tested and accredited functional by OIM. Platform is ready operating using instrument air systems. On remote platform, alternative alarm will be provided by operation and all contraction crew must familiar with the alarm.

    1.8 Safety Requirement and Precautions:

    Normal hazardous area classification shall govern. The safety requirement and precautionary works shall be implemented as detail in this pre and post shut down procedure.

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    2. SCOPE OF WORK

    2.1 WORKSCOPE SUMMARY AS PER LOCATION

    The summary of planned shutdown and pre shut down activities to be carried out for Samarang Platforms by contractors and operation as following:

    2.1.1 SMQ-A/SMG-A (1) RV’s rectification by Wehaya (on passing isolation valves)

    (2) PM & Punch list clearance for ASD and PMCS. (SD)

    (3) LPS-4026 – replace corroded 1” tapping line. (SD)

    (4) PCV-3151 & PCV-3152 valve replacement (NSD)

    (5) PCV-3430 & PCV-3420 (NSD)

    (6) LCV-3060 (NSD)

    (7) PLC for SDS to be reset. (SD)

    (8) BC3091 readjust voltage. Increase supply voltage. (SD)

    (9) Hook-up connection for spare MCB (UPS1/2) - SUMANDAK field project.(SD)

    (10) Vent stack obstruction light replace blown bulb and check lamp changer. (SD)

    2.2.2 SMV-A (1) Marine lantern check (SD)

    (2) NTD check by STS/2

    2.2.3 SMP-A (1) PCV-201A replacement (SD)

    (2) PCV-2000 replacement (SD)

    (3) 3-way valve fuel gas replacement (SD)

    (4) 2” condensate line from SMV-AA (SD)-DYG

    (5) Header ball valve change out. (SD)

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    (6) PL-133 inspection & repair.(NSD) Allied Marine (7) PL-132 LP vents line. (NSD) Allied Marine

    (8) Receiver door barrel from SMP-C replacement. (SD)

    (9) RV’s rectification. (SD) Wehaya

    2.2.4 SMDP-A (1) Replace kill knob stand.(SD)

    (2) Install extra SR on kill knob line from SANCOP.(SD)

    (3) 2” instrument air piping replacement.(SD)-DYG

    (4) 1” instrument pipe change out on SR-2A, 2B & 3. (SD)

    (5) 4” drain line to sump tank replacement.(SD)-DYG

    (6) 4” Blown down line replacement. DYG

    (7) Replace blown down valve underneath wellhead area.

    (8) Repair corroded grating. DYG

    (9) Blow down valve change out – OT

    (10) RV’s rectification. (SD) Wehaya Service SD SR.

    (11) Gas lift pipe and headers cut and replacement. (SD)

    2.2.5 SMP-B (1) PL-139 sectional pipe replacement. (SD) Allied Marine

    (2) Riser repair punch list : 10” R6- LP to SMG-A. (NSD) Corroshield

    (3) Header ball valves replacement. SM-58L (HP valve), SM50L (All valves) (SD)

    (4) 8” LP vent line check valves replacement. (SD)

    2.2.6 SMDP-B (1) Header ball valves replacement. (SD) [Sm-60L – LP; 60S-HP; 53S-Test; 64L

    – all valves and flow line; 58S-flowline. (2) Replace handrail on chemical tank required hot work. (SD) (3) 2” gas lift replacement. Alab-3 ; SM-51 & SM-65. (SD)

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    (4) Angle iron support for LCV-301.

    2.2.7 SMV-B (1) Marine lantern inspection. (SD)

    (2) Vent stack inspection by STS-2.(SD)

    2.2.8 SMP-C (1) 8” vent line butterfly valve replacement.(SD)

    (2) Install 1 ball valve for water sample on V-300.(SD)

    2.2.9 SMJT-C (1) Replace 3/8” parted tubing from PSD-01. (SD)

    (2) Service 2” Big Joe regulator for S-1 from HHP.(SD)

    (3) Riser repair punch list ; LP ‘B’ to SMP-A. (SD) Corroshield

    (4) Replace handrail sockets (Hotwork) SD

    2.2.10 SMV-C (1) Marine lantern inspection. (SD)

    (2) Vent stack inspection by STS-2.(SD)

    2.2.11 SMJT-D (1) Remove 2 pieces check valves on incoming lines SMJT-F.(SD)

    (2) Riser repair punch list. (SD) Corroshield

    (3) Unblock S1 drain line.(NSD)

    (4) 4” Drain ball valves on Receiver R-117 replacement.

    (5) Replace 2” x 600# header ball valve for HHP – SD

    2.2.12 SMJT-F (1) Remove 2 pieces check valves lines to SMJT-D.(SD)

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    (2) Unblock S1 drain line.(NSD)

    (3) Replace 6” orifice box on main gas lift header (SD)

    (4) Replace 2” x 600# header ball valve for HHP – SD

    2.2.13 SMJT-G (1) Replace 6” orifice box on gas lift header.(SD)

    (2) Replace 2” x 600# header ball valve for HHP - SD

    3 Shut Down Guideline For SMG-A

    Pre-shutdown task: 14/09/2004 @ 0800 hrs

    (1) Run close and open drain pumps to empty the sump pile

    (2) Run condensate pump to empty the free water knock out drum on SMV-AA. (task – replace condensate line)

    Shut down Guideline: 3.1 Establish proper communication with LGAST, KNDP-A and SMP-A prior to

    reduce export to LGAST.

    3.2 Ram down HP and LP compressors.

    3.3 Run standby diesel generator (G-3670) before shutting down gas turbine generator.

    3.4 Bring down vessel level to minimum.

    3.5 Wait for SMP-A to initiate ESD by pulling kill knob from SANCOP.

    3.6 After ESD trigger, check for vessel pressure and level. If still have pressure trap inside, depressurize the vessel.

    3.7 Check for common ABV, ROV, BDV and equipment trip as per logic.

    All start-up sequence can be referred in the startup procedure manual

    REMINDER!

    NO HOT WORK IS ALLOWED DURING FLANGE BREAKING, DEPRESSURIZATION, DRAINING AND LINE FLUSHING.

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    GAS TEST `TO BE CARRIED OUT PRIOR TO ANY OF THE HOT WORK. 4 Shut Down Guideline For SMP-A/SMDP-A/SMJT-G/SMJT-E

    Pre-shutdown task:

    (1) Run sump pumps to empty sump pile (SMP-A) and sump tank (SMDP-A) (task – Hot work on SMP-A and replace drain line, blow down line for sump tank at SMDP-A)

    (2) Carry out vent line flushing on all line. (SV & HP)

    Shutdown Guideline:

    4.1 Establish proper communication with SMG-A, CCR, LCOT and KNDP-A prior to reduce intake and export.

    4.2 By-pass ASD-01 prior to shut down the station. (for lowering level)

    4.3 Ram down HHP compressor until no load or minimum speed.

    4.4 Run standby diesel fire water pump.

    4.5 Inform KNDP-A to shut down their station.

    4.6 Close in flowing wells when the HHP static reach 500psig or minimum pressure. (Last well to close SM9L, 6L, 16S, 17L ; high water cut)

    4.7 Bring the HP vessel (V-100A) level to minimum. (task replace PCV-201A)

    4.8 The surge vessel (V-300A) level to minimum. (task replace 20” ball valve if valve arrive on time)

    4.9 Monitor the pumps and if needed put one export pump on manual during lower down the surge vessel level. At minimum level, stop the pump manually to prevent cavitations.

    4.10 Once minimum level is reached, initiate ESD by pulling kill knob at SANCOP module. Monitor the time delay for SANCOP’s kill knob to trigger ESD. If not triggered, instrument personnel to check and rectify the problem.

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    4.11 After ESD triggered, ensure all rotating equipment are brought to stop and vessels fully depressurized.

    4.12 Record all ABVs and BDVs position.

    4.13 At SMDP-A, isolate :

    (1) 6” main gas lift manual ball valve

    (2) 2” individual line gas lift valve

    (3) individual valves on the headers to wellheads

    (4) gas lift valves on the wellhead

    (5) master valves etc.(task – replace main and individual gas lift headers,

    valves and piping)

    4.14 At SMP-A, close all header ball valves, COTP on off mode, bring up the orifice plate to top position of the orifice box and put tagging of isolation.

    4.15 Normalize ASD and PPP panel.

    4.16 Proceed to do shutdown jobs.

    4.17 SMJT-E and SMJT-G will shutdown when SMP-A ESD.

    4.18 Personnel onboard SMJT-G and SMJT-E will carry out shutdown sequence. If the station does not ESD, pull kill knob and check shutdown sequence.

    4.19 Close all valves on wellhead.

    4.20 At SMJT-G, isolate :

    (1) The main gas lift header

    (2) Individual gas lift valve

    (3) Gas lift valve on the wellhead. (task – replace 6” orifice box )

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    EQUIPMENT AND PROCESS LINE NEED FLUSHING AND DEPRESSURIZATION

    1. Condensate line from SMV-AA to SMP-A – flush and depressurize

    2. Drain line to sump tank SMDP-A – flush

    3. Drip pan SMP-A – flush and washdown

    4. Blow down line SMDP-A – flush

    5. LP and Test headers – depressurize and drain

    6. Instrument air line SMDP-A –depressurize

    7. S-1 – depressurize

    8. V-100 PCV-201 - depressurize

    9. V-300A – drain (depending on 20” ball valve availability)

    10. LP gas line to SMG-A PCV-2000 – depressurize

    11. Main and individual gaslift header SMDP-A – depressurize and flush

    12. Main gas lift header on SMJT-G - depressurize

    All start-up sequence can be referred in the startup procedure manual.

    REMINDER!

    NO HOT WORK IS ALLOWED DURING FLANGE BREAKING, DEPRESSURIZATION, DRAINING AND LINE FLUSHING.

    GAS TEST `TO BE CARRIED OUT PRIOR TO ANY OF THE HOT WORK.

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    5. Shut Down Guideline For SMP-B/SMDP-B

    Pre-shutdown task: (1) Run both sump pumps on SMP/SMDP-B to empty sump pile and tank.

    (2) Carry out vent line flushing and rocking LP pipeline.

    Shut down Guideline:

    5.1 Establish proper communication with SMG-A, CCR, ICR and SMP-A prior do the vent line flushing, rocking and close in well.

    5.2 Close in high crude producing wells and let high water cut wells flowing for 3 hours. (SM42S, 51L, 60S, 57S, 66S ; high water cut wells) (task- pipeline sectional cut under water PL-139)

    5.3 Manually isolate the LP ABV to SMGA on the cellar deck for pipeline total depressurization. (Corroshield task)

    5.4 Inform CCR and SMP-A prior shuting down the station. Pull kill knob.

    5.5 Carry out ESD check on all ABV and BDV as per logic. All vessels depressurized.

    5.6 Close all flow line valves, wing valves and all header valves SSV as per logic. (task – flow line change out)

    5.7 Depressurize the HP, LP and test headers. If required, depressurize HHP header. (Task - ball valves header and flow line change out)

    5.8 Normalize all ASD and PPP.

    5.9 Proceed with shutdown jobs.

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    EQUIPMENT AND PROCESS LINE NEED FLUSHING AND DEPRESSURIZATION

    (1) HP, LP and Test headers at SMP-B & SMDP-B – depressurize and drain.

    (2) Vent lines – depressurize on upstream.

    (3) Main and individual gas lift header SMDP-B - depressurize

    All start-up sequence can be referring in the manual startup procedure.

    REMINDER!

    NO HOT WORK IS ALLOWED DURING FLANGE BREAKING, DEPRESSURIZATION, DRAINING AND LINE FLUSHING.

    GAS TEST `TO BE CARRIED OUT PRIOR TO ANY OF THE HOT WORK.

    5. Shut Down Guideline For SMP-C/SMJT-C/SMJT-D/SMJT-F

    Pre-shutdown task:

    (1) Run both sump pumps on SMP/SMJT-C to empty sump pile.

    (2) Carried out vent line flushing and rocking LP pipelines.

    Shut down Guideline:

    5.1 Establish proper communication with SMG-A, CCR, ICR and SMP-A prior carryingout vent line flushing, LP line rocking and ESD test. 5.2 By-pass ASD-001, PPP and manually isolate supply to ABV on LP gas

    pipelines to SMP-A prior shuting down the station. (Corrosheild and DESB task)

    5.3 Inform SMJT-F first to close in all following wells.

    5.4 Allow SMJT-D to flow only high water producing wells for 1-2 hours. (31S,41S & 34L)

    5.5 Monitor COTP’s pump and bring down the Surge vessel level to minimum.

    5.6 Close all wells at SMJT-C wells except SM19S and 85S.

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    5.7 Pull kill knob from SMJT-C boat landing. (to check functionality)

    5.8 Check that LP pipeline to SMP-A is totally depressurized.

    5.9 Carry out ESD check on all ABV and BDV position as per logic.

    5.10 Isolate all flow line valves.

    5.11 Normalize the isolation valves to ABV (LP gas to SMP-A) after depressurization.

    5.12 Normalize all ASD and PPP.

    5.13 Proceed with shut down job.

    SMJT-F

    1. Shut down station by pulling kill knob.

    2. Close in all wells by isolating flow line valves.

    3. Check ABV position, as per logic.

    4. Normalize the kill knob.

    SMJT-D

    1. Close in wells except SM-31S, 41S & 34L. (high water cut)

    2. Estimate the wells to flow for 1-2 hours.

    3. Contact SMP-C before pulling kill knob after 1-2 hours

    4. Check the station status after ESD.

    5. Normalize the kill knob before leaving the station.

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    EQUIPMENT AND PROCESS LINE NEED FLUSHING AND DEPRESSURIZE 1. All LP gas pipeline to SMP-A – depressurize.

    2. Vent lines – depressurize upstream.

    3. LP pipeline from SMJT-D

    REMINDER!

    NO HOT WORK IS ALLOWED DURING FLANGE BREAKING, DEPRESSURIZATION, DRAINING AND LINE FLUSHING.

    GAS TEST `TO BE CARRIED OUT PRIOR TO ANY OF THE HOT WORK.

    Prepared by : Yousof Ahmad Reviewed by: .......................................... John Masudal Samarang Ops Supv .......................................... M Anton Abdullah Samarang Senior Ops Supv Aproved by: ........................................... Thamilarasu SK Samarang OIM ........................................... M Johari Amir Samarang OIM

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    APPENDIX 2

    SAMPLE CHECKLIST OF TEMBUNGO INTEGRATED SHUTDOWN SEQUENCE

    TBG Shutdown Sequence (Shutdown Driver: Vessel Cleaning)

    23/01/09 @ 0700hrs (Friday)

    Time Task Action Party Check

    0700 TBG A/B team to empty sump caisson. TBG A/B (HM,MM, AF)

    1530 Toolbox meeting with contractors. (Contractor to prepare and submit PTW for next day, checklist preparation) All

    Distribute ESD,PASR checklist.

    1700 Power Transfer @ TBG A (G-500 to G-510) TBG A Elect/Mech

    Ensure C-520 and P-400 is on duty before power transfer. Switch back to C-510 and P-320 after power transfer.

    TBG A Elect/Mech

    2000 Start lowering down liquid level for LP & HP flare scrubber liquid. Night Shift (SL,NL)

    Empty sump pumps MOD 2,Prod Deck Night Shift (SL,NL)

    Bypass V-200 and V-150 LSL and PSL. Night Shift (SL,NL)

    TBG A start to lower down V-200 and V-150 liquid level. Night Shift (SL,NL)

    Set LIC 5% for V-200 and V-150 Night Shift (SL,NL)

    Ensure V-200 and V-150 level reach to the lowest point. Night Shift (SL,NL)

    2300 Team depart to TBG B TBG B (AF,AW,NM)

    2330 Team ready at TBG B TBG B (AF,AW,NM)

    Ensure all systems are ready for shutdown mode. TBG B (AF,AW,NM)

    2350 Inform EW CCR on pre-shutdown tasks. Night Shift (SL)

    Inform TBG B if everything is ready for ESD activation Night Shift (SL)

    24/01/09 @ 0000hrs (Saturday)

    Time Task Action Party Check

    0000 To close in high liquid producing wells B8-L & B1-L. (to reduce trunkline pressure from TBG B to TBG A) TBG B (AF,AW,NM)

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    0010 Activate TBG B ESD by kill knob and inform TBG A TBG B (AF,AW,NM)

    Go through ESD check list. TBG B (AF,AW,NM)

    Manually close flow line and wing valve for all wells and start TBG B system depressurization. TBG B (AF,AW,NM)

    Normalize S-315 gas scrubber by nitrogen to open up SDV-2501 and monitor trunkline pressure to 0 psi.

    TBG B (AF,AW,NM)

    After trunkline pressure reach the lowest point inform TBG A. TBG B (AF,AW,NM)

    0015 CCR panelman to activate ESD by killknob before LSL-200 reach the setpoint. CCR (SL,IBT,HM)

    Inform EW CCR on shutdown activation confirmation. CCR (SL)

    Go through ESD check list. Night Shift (SL,NL)

    0030 Manually close flow line and wing valve for all wells. Night Shift (SL,NL)

    0040 Tour check at site to ensure all pressure and level reached the lowest point. Night Shift (SL,NL)

    0100 Stop Mol Pump P-140 when V-150 level reach 0% on LIC reading. Night Shift (SL,NL)

    Manually drain V-200 and V-290 to caisson Night Shift (SL,NL)

    Pump up skimmer pile. Night Shift (SL,NL)

    Line up SDV-155 and SDV-165 Night Shift (SL,NL)

    Restart P-140 to reduce V-150 level. Night Shift (SL,NL)

    Prepare for LOTO All

    Wait for complete depressurization Process

    0200 TBG B team depart back to TBG A TBG B (AF,AW,NM)

    0400 Extinguish flare (purge with nitrogen) Night Shift (SL,NL)

    0430 LOTO on P-120,P-130,P-140,P-100 and complete check on ALL isolations.

    Elect/Process (NJT,SL)

    0600 Toolbox meeting (PTW, checklist preparation) All

    0615 Handover to shutdown project teams All

    0730 Team depart to TBG B TBG B (AS,MM)

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    APPENDIX 3

    SAMPLE CHECKLIST OF TEMBUNGO INTEGRATED STARTUP SEQUENCE

    TBG Start-Up Sequence

    TBG A Start-Up Sequence

    Time Task Action Party Check

    Ensure all the purging for vessel have been done Process

    Tour check to identify isolation, spading removal of all associated line (refer to checklist) Process

    Inform EWPA before start up CCR

    Perform the following system check : Process

    a. Portable air compressor is online and supply enough pressure for instrumentation.

    b. L-160 & R-170 total shutdown switch on bypass

    c. Gas compressor on bypass

    d. Wellhead control panel on bypass

    e. SDV 155 & SDV 165 opened

    f. SDV-200 & SDV-290 opened

    g. Header valve to production separator opened

    h. Ensure that all natural producing well’s choke beans are set to the lowest size

    i. Ensure all AGV for flowing wells are in open position

    j. Ensure the blowdown valve in close position

    Inform TBG B operation to start up station (go through TBG B start up sequence) Process

    Pressure up all hydraulic supply to ScSSV. Open the master valve and then the SSV Process

    Open the wing valve very slowly until the SITHP gradually falls equal to the FTHP. Process

    Start the MOL pump when V-150 level reach 40 to 50 %. Electrical

    Start the chemical injection pump. Process

    Monitor V-210 pressure and start up Gas Compressor.(Check the V-210 for fuel gas supply pressure before initiate)

    Process/ Mechanical

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    Return the flowing panel to normal operation mode : CCR

    a. Acknowledge and reset annunciator panel.

    b. L-160 & R-170 switch to normal.

    c. Gas Compressor bypass on normal

    d. Reset flow computer alarms

    Ignite flare Process

    Tour check again to ensure all normally open valve are in open position and all normally close valve is in close position. All

    TBG B Start-Up Sequence

    Time Task Action Party Check

    Ensure all spades have been remove by following the checklist. Process

    Plug-off SDV-315 exhaust port Process

    Bypass 'ESD bypass' button Process

    Pull all 'PSD bypass' button & 'PSHL bypass' button at the Autocon module Process

    Inject nitrogen to open SDV-315 (instrument gas scrubber) Process

    Inform TBG A before opening SDV-2501 (line to TBG A) Process

    Open up 1 well to supply enough pressure to instrument gas scrubber. Process

    O/up all wells one by one Process

    Monitor station until stabilize Process

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    PETRONAS CARIGALI SDN BHD APPENDIX 4 Page A4-1

    APPENDIX 4

    SAMPLE OF SMG-A COOLER SPADING AND ISOLATION LIST

    SMG-A COOLER SPADING & ISOLATION LIST E-3095 & E-3105

    ISOLATION

    NO TAG &

    DESCRIPTION ISOLATION

    DONE DATE OPERATION TECHNICIAN

    PROJECT ENGINEER

    OPERATION SUPERVISOR REMARKS

    1 E-3095 LUBE OIL COOLER’S INLET & OUTLET 4” FLANGES.

    (2 UNITS)

    20/08/03 Patrick Edwin M Anton

    2 E-3105 - GAS COOLER INLET 6” FLANGES

    (3 UNITS).

    20/08/03 Patrick Edwin M Anton

    3 E-3105 - GAS COOLER OUTLET 6” FLANGES

    (3 UNITS).

    20/08/03 Patrick Edwin M Anton

    4 HOV-3094

    SUCTION MANUAL VALVE CLOSED.

    20/08/03 Patrick Edwin M Anton

    5 HOV-3096

    DISCHARGE MANUAL VALVE CLOSED

    20/08/03 Patrick Edwin M Anton

    6 PSV-3095

    MANUAL VALVE

    CLOSED

    20/08/03 Patrick Edwin M Anton

    7 GT-3095 L/OIL TO E-3095 MANUAL VALVE CLOSE

    (NEAR GT-3095 SKID)

    20/08/03 Patrick Edwin M Anton

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    DE-ISOLATION

    NO TAG &

    DESCRIPTION

    DE-ISOLATION

    DONE DATE

    OPERATION TECHNICIAN

    PROJECT ENGINEER

    OPERATION SUPERVISOR

    REMARKS

    1 E-3095 LUBE OIL COOLER’S INLET & OUTLET 4” FLANGES.

    (2 UNITS)

    27/08/03 Patrick Edwin Boneface

    2 E-3105 - GAS COOLER INLET 6” FLANGES

    (3 UNITS).

    27/08/03 Patrick Edwin Boneface

    3 E-3105 - GAS COOLER OUTLET 6” FLANGES

    (3 UNITS).

    27/08/03 Patrick Edwin Boneface

    4 HOV-3094

    SUCTION MANUAL VALVE CLOSED.

    29/08/03 Patrick Edwin Boneface

    5 HOV-3096

    DISCHARGE MANUAL VALVE CLOSED

    29/08/03 Patrick Edwin Boneface

    6 PSV-3095

    MANUAL VALVE

    CLOSED

    29/08/03 Patrick Edwin Boneface

    7 GT-3095 L/OIL TO E-3095 MANUAL VALVE CLOSE (NEAR GT-3095 SKID)

    29/09/03 Patrick Edwin Boneface

    Prepared by, Acknowledgement By OIM :

    _______________________ ___________________________

    Patrick Pterus. M Johari Amir.

    Operation Process/Instrument Tech. Platform Superintendent. Date : Date :

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    PETRONAS CARIGALI SDN BHD APPENDIX 5 Page A5-1

    APPENDIX 5

    SAMPLE OF TBG INTEGRATED PLAN ON PAPER (iPOP)

    V-290 PL Welltest By Pass Line Modification

    ACTIVITIES Materials Resources Who’s responsible? Clashes w/ other activities

    HSE Issues Correction Action Parties

    /Mitigation

    PRE – SHUTDOWN ACTIVITIES

    Mob Project Materials 25% Tarmazi no no Tarmazi SV

    Mob Manpower no yes 100% Tarmazi no no Tarmazi SV

    Site Preparation yes yes Tarmazi yes no Tarmazi SV

    Odd Bolting no yes Tarmazi yes hand finger injury gloves/ proper tchq Tarmazi SV

    SHUTDOWN ACTIVITIES

    USD V-290 no yes OPR yes, VC

    SD Welltest System no yes E&I / Opr no no

    Remove existing spool no yes Tarmazi no spillage, pressure trap canvas, bleed before remove

    Tarmazi SV

    Blind Off incoming/outgoing line yes yes Tarmazi no spillage Canvas Tarmazi SV

    Modify existing line yes yes Tarmazi/Opr yes, Workover Rig Down

    HC existance in spool Cleaning before HW Tarmazi SV

    RT & HT yes yes RT team/ Tarmazi/Opr

    All activities Radiation, High pressure Midnight, barricade, announcement

    Tarmazi SV / OPR

    Re-instate back line yes yes Tarmazi yes, VC congested area Tarmazi SV

    Power up energize system no yes tarmazi no no Tarmazi SV / OPR

    POST- SHUTDOWN ACTIVITIES

    Touch-up painting yes yes tarmazi yes fume PPE Tamarzi

    Flanges greasing yes yes tarmazi yes no

    Install U-Bolt & neoprene sheet yes yes tarmazi yes figer injury gloves Tamarzi

    Housekeeping no yes tarmazi yes no

    Rig down Equipment no yes tarmazi & opr yes ergonomic, heavy lift proper technique Tamarzi/OPR

    Demob no yes trmazi no no

  • Pre-Activity Safety Review WW ALL S 04 010 Appendices Rev. 1, Dec 2010

    PETRONAS CARIGALI SDN BHD APPENDIX 6 Page A6-1

    APPENDIX 6

    Sample of Pre-Shutdown Safety Review Checklist

    No Descriptions Findings Remarks

    Yes No N/A

    Work planning

    1. Work permit is written and obtained prior to commencement of respective activity.

    2. Work scope has been discussed and agreed on with operations, contract holder and contractors.

    3. Number of personnel carry out respective work is planned and identified, including shift work.

    4. No. of pax on platform is planned, closely monitored and comply to PCSB requirement.

    5. Coordination meeting is conducted with involvement from all parties; shutdown plan is developed.

    6. Weather condition is taken into account prior to commencement of work.

    7. Materials/ parts required for shutdown activities are checked and available at site.

    8. Inspection and calibration of equipments/ tools is completed (including tools brought in by contractors)

    9. Tools and consumables list is available.

    10. All portable equipments are inspected and certified prior to site placement.

    11. Shutdown procedure (from shutdown to startup), workpack or site-specific procedure is prepared and approved by management.

    12. MOC is raised and approved by TA for modification in process or equipment prior to commencement of activity.

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    13. Operating manual (OPM), Hazard and Effect Register (HER) and other relevant documents are available at site for quick reference

    14. All trainings required for shutdown activities are completed (both PCSB staff and contractors).

    15. All outstanding items have been cleared prior to commencement of activity; otherwise management approval must be granted in order to proceed with open items.

    16. Site preparations activities have been completed as per shutdown plan, include:

    - erection of scaffolding - utilities set-up - hot bolting(if any) - insulation removal - spade placement/marking (spading list) - temporary equipment inspection & certification - preparation of relevant barriers/ safety

    signage etc.

    17. Locks (LOTO) are available and adequate.

    18. Barricades are available and adequate.

    19. Safety officer is identified.

    20. Identified area fenced for authorized personnel only.

    21. Communications means (radio, GPA etc.) is available and functioning.

    22. Pre-mobilization briefing has been conducted for all contractors and staff.

    Hydrocarbon liquid

    1. Area is free of hydrocarbon.

    2. Fire blanket is available.

    3. Draining/ bleeding route is checked.

    4. Adjacent pipework is leak free.

    5. Containers, sumps, pits are prepared/ empty.

    Hydrocarbon gas

    1. Gas detectors and fire detectors are available and functioning.

    2. Gas testing equipment is available and functioning.

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    Non-hydrocarbon gas under pressure in pipework (test by N2)

    1. N2 purging equipment and supply are available and adequate.

    2. Warning signage on pressure testing is available and visible.

    Bottled gas under pressure

    1. Gas bottles are stored at safe area and properly secured with wire rope.

    2. Gas bottles are equipped with flashback arresters and check valve.

    3. Gas bottles are certified and color-coded.

    Diesel

    1. Integrity check on diesel tank is done.

    2. Diesel tank is earthed.

    3. Diesel is sufficient for shutdown duration.

    Overhead/ lifting equipment

    1. All lifting gears are checked and certified.

    2. Actual weight of the load is confirmed.

    3. Lifting plan is prepared and discussed with operations & contractors.

    4. Load chart of the crane is correct.

    5. Crane standing area is firmed and flat.

    6. Integrity check is done (using crane inspection checklist).

    7. No unnecessary activities in lifting area.

    8. Fire extinguishers, fire hose, and firewatcher are ready.

    9. All alarm and emergency system of the crane is checked and functioning.

    10. Number of personnel in the lifting area is minimized; access is restricted.

    11. Clear escape routes are available.

    12. Lifting coordinator is identified.

    13. Crane operator is trained and qualified.

    14. Crane signaler is trained and qualified.

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    Equipments with rotating parts

    1. Ensure sufficient clearance for machine operation.

    2. Moving parts are properly covered with guards.

    3. Appropriate tools are ready for machine operation.

    4. Ensure air, water and steam hoses are properly secured.

    5. Access is restricted to authorized personnel.

    Pressure vessels/ tanks/ separators

    1. Ensure sump pile, sump tank, sump caisson and drip pan are empty.

    2. Ensure liquid level is at lowest possible level.

    3. Draining/ bleeding route is checked.

    4. Ensure no hot work in the bleeding area.

    5. Area fenced for authorized personnel only, if required.

    6. Wind direction is checked. Gas plume is checked and considered safe.

    7. Gas detectors are available and functioning at the nearby working area.

    8. Fire extinguishers, fire hose, firewatcher are ready.

    9. Tanks, vessels or work pieces are properly earthed.

    Mechanical isolation

    1. Ensure that spades are in right location (refer to startup and shutdown procedure).

    2. Spectacle blinds are turned to correct position (refer to startup and shutdown procedure).

    3. Valve opening/ closing sequence for shutdown activities are part of shutdown procedure and communicated to relevant personnel.

    4. Pipe specifications are as per designed (refer to P&ID).

    Instrument settings

    1. Pressure safety valve (PSV) or Relieve valve (RV) settings are as per designed (refer to P&ID).

    2. Ensure all instruments settings are as per designed (refer to P&ID) :

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    PETRONAS CARIGALI SDN BHD APPENDIX 6 Page A6-5

    PAH/PAHH PAL/PALL LAH/LAHH LAL/LALL TAH/TAHH TAL/TALL

    3. Ensure all gauges & transmitters are available as per P&ID and functioning : PG/PT TG/TT LG/LT FT, flowmeter

    4. Fire detection and protection equipments are functioning.

    Electrical isolation

    1. Equipments/ tools are checked for electrical safety.

    2. Locks (LOTO) and isolation tags are available and adequate.

    3. Personnel are trained and qualified.

    Confined space

    1. Blower is available and functioning for sufficient ventilation.

    2. BA sets/ oxygen feeder are available, adequate and functioning.

    3. Fire extinguishers, fire hose, firewatcher are ready. Firewatcher is trained and qualified.

    4. No. of personnel working in confined space is planned and trained (including shift work).

    5. Portable gas detector is available and functioning.

    6. Access and egress are prepared.

    7. Sufficient lighting is prepared.

    8. Dust mask is available.

    9. Proper tools for collecting and cleaning the sludge are available.

    10. Temporary de-contamination room is available, if required.

    11. Sunshade is available.

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    PETRONAS CARIGALI SDN BHD APPENDIX 6 Page A6-6

    12. Area is fenced and warning sign is installed.

    Gamma rays closed source type - radiography

    1. Source container is checked for integrity.

    2. Area is fenced for authorized personnel only.

    3. Dosimeters for radiographers are available and functioning.

    4. Max. exposure of gamma ray at the edge of the fence is checked.

    5. Proper lead shields are available.

    6. Source recovery or emergency tools are available.

    7. Warning sign is installed and visible.

    8. Radiographers are physically fit and certified.

    Arc, gas and electrical welding

    1. Proper PPE is available (welding mask, leather gloves, etc).

    2. Welding curtain is prepared.

    3. Access is restricted.

    4. Welders are trained and certified.

    5. Welding equipment is available, functioning, and checked for electrical safety.

    6. Welding cable is in good condition.

    7. Equipments are properly earthed, as required.

    8. For gas acetylene welding/ cutting, cylinder tanks must be segregated during welding activities and stored separately.

    9. Fire extinguishers, fire hose, firewatcher are ready. Firewatcher is trained and qualified.

    Person working at height

    1. Safety harnesses are available.

    2. Scaffolding is erected by trained & certified personnel, and inspected by certified inspector.

    3. Barricade the area underneath the scaffold or platform.

    4. Adequate means to transport tools and equipment.

    Health check for PCSB staff and contractors

    1. Ensure all personnel working onboard are physically

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    fit to work.

    2. Blood and urine test for personnel working on mercury.

    3. Drug and alcohol test for personnel working onboard.

    Emergency response

    1. ERP document is available at site.

    2. Staff is familiar with roles and responsibility of ERT and EMT.

    3. Staff is familiar with escape routes.

    4. Members of DCT are trained and familiar with fire fighting equipments.

    5. Staff is familiar with alarm system and aware of the mustering point.

    6. Staff is aware of the location of life saving equipments.

    Additives

    1. For long duration shutdown, ensure that sufficient amount of corrosion inhibitor and biocide are available for the injection to relevant pipelines, if required.

    2. For facilities with waxy crude, ensure that sufficient amount of demulsifier is available for injection to relevant pipelines.

    Storage area

    1. Dedicated storage area for materials and scheduled waste.

    2. Chemicals are segregated accordingly.

    3. Copy of MSDS is available at storage area.

    4. Ensure proper labeling is displayed.

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    PETRONAS CARIGALI SDN BHD APPENDIX 7 Page A7-1

    APPENDIX 7

    SAMPLE OF PRE-STARTUP SAFETY REVIEW CHECKLIST

    No Descriptions Findings Remarks

    Yes No N/A

    Work planning

    1. All work permits are signed off accordingly.

    2. All construction works is completed and appropriate reports signed off by platform authority.

    3. No. of pax on platform is planned, closely monitored and comply to PCSB requirement.

    4. Coordination meeting is conducted with involvement from all parties; startup plan is developed.

    5. Weather condition is taken into account prior to startup.

    6. Used materials/ parts are properly segregated and disposed off.

    7. Equipments/ tools are returned to store/ warehouse, or brought back by contractors.

    8. Tools and consumables list is checked.

    9. All portable equipments are checked and removed from site.

    10. Startup procedure, workpack or site-specific procedure is prepared and approved by management.

    11. Applicable MOC requirement is met.

    12. PHA/HAZOP has been performed and recommendations have been resolved or implemented before startup.

    13. Operating manual (OPM), Hazard and Effect Register (HER) and other relevant documents are available at site for quick reference

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    14. All trainings required for operating the process are completed (both PCSB staff and contractors).

    15. All outstanding items have been cleared prior to startup; otherwise management approval must be granted in order to proceed with open items.

    16. Site clean-up have been completed as per startup plan, include:

    - Dismantle of scaffolding - Removal of utilities - Insulation installed - removal of spade - removal of temporary equipment - removal of relevant barriers/ safety signage

    etc.

    17. Locks (LOTO) are checked and removed accordingly.

    18. Barricades are removed after work completion.

    19. Safety officer is on site.

    20. Identified area fenced for authorized personnel are removed.

    21. Communications means (radio, GPA etc.) is available and functioning.

    22. Safety rules or signs, as needed, have been posted.

    23. PPE required for new equipment or chemicals are available prior to startup.

    24. Tool box meeting is conducted on daily basis to ensure work carried out in a safely manner.

    Hydrocarbon liquid

    1. Area is free of hydrocarbon.

    2. Gas detectors and fire detectors are available as per P&ID.

    3. Draining/ bleeding route is checked.

    4. Adjacent pipework is leak free.

    5. Equipment is installed as per design specification.

    6. Hydro-testing, tightness, and pressure tests have been completed with satisfactory results.

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    7. Leak check is performed.

    8. Process line is purged with inert or N2 gas.

    9. Warning signage on pressure testing is removed.

    10. Fire extinguishers and fire hose are available.

    11. Fire blanket is available.

    Hydrocarbon gas

    1. Gas detectors and fire detectors are available as per P&ID.

    2. Equipment is installed as per design specification.

    3. Hydro-testing, tightness, and pressure tests have been completed with satisfactory results.

    4. Gas testing is completed.

    5. Process line is purged with inert or N2 gas.

    6. Warning signage on pressure testing is removed.

    7. Fire extinguishers and fire hose are available.

    Bottled gas un