ENGINEER’S STAMP: CONTRACTOR’S STAMP:

Signature

Ab Issue for Approval CZ CZ MPJ 20130308

AA Issue for Approval CZ CZ MPJ 20130122
REV DESCRIPTION PREPARED CHECKED APPROVED DATE

KINGDOM OF SAUDI ARABIA ‫الـممـلـكــة العــربـيــة الســعـوديـــة‬

‫المـؤســســــة العــامــة لتحــلـية الـمــيــاه الـمــالــحــة‬
SALINE WATER CONVERSION CORPORATION

‫محطة تحلية المياه المالحة وتوليد الطاقة الكھربائية رأس الخيــر – المرحلـة االولـى‬
RAS AL KHAIR POWER AND DESALINATION PLANT-PHASE 1

PÖYRY ENERGY AG

SEPCOIII ELECTRIC POWER CONSTRUCTION CORPORATION

PROJECT: TITLE:
31002
LOCATION:
East Coast HSE COMMISSIONING PLAN
PACKAGE:
“P” Power Plant
SCALE: DOCUMENT No.: REV:
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Engineer of Record Sheet 1 of 38

 Section Index

1.  Introduction .......................................................................................................................................... 3 

2.  Project Description...............................................................................................................................3 
3.  Definition and abbreviations ................................................................................................................ 4 
3.1  Definitions ..................................................................................................................................... 4 
3.2  Abbreviations ................................................................................................................................ 5 
4.  Reference ............................................................................................................................................ 5 
5.  HSE responsibilities and organization ................................................................................................. 6 
5.1  HSE Organisation ......................................................................................................................... 6 
5.2  HSE Function and Responsibilities .............................................................................................. 8 
5.3  Sub-Contractors personnel and Vendors Specialists ................................................................... 9 
6.  HSE objectives during pre-commissioning and commissioning ........................................................ 10 
7.  Pre-commissioning and commissioning activities .............................................................................. 10 
7.1  Pre-Commissioning .................................................................................................................... 10 
7.2  Commissioning .................................................................................................错误!未定义书签。 
8.  HSE activites during commissioning phase ....................................................................................... 11 
8.1  HSE Training .............................................................................................................................. 15 
8.2  HSE Meetings ............................................................................................................................. 15 
8.3  Emergency Response Planning ................................................................................................. 15 
8.4  Work Permit System ................................................................................................................... 16 
8.5  Site Access and Security Procedure .......................................................................................... 19 
8.6  Lock Out and Lock Out Procedure ............................................................................................. 19 
8.7  System Isolation ......................................................................................................................... 19 
8.8  Job safety analysis ..................................................................................................................... 19 
8.9  Chemical Handling and MSDS ...................................................................................................19 
8.10  Accident Investigation, Reporting and Follow-up ....................................................................... 20 
8.11  Health ......................................................................................................................................... 20 
8.12  Environment ............................................................................................................................... 21 
8.13  HSE Inspection and Monitoring .................................................................................................. 21 
8.14  SIMOPS ...................................................................................................................................... 22 
8.15  HAZID report .............................................................................................................................. 22 
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1. Introduction

Purpose of this document is to describe the HSE requirements for the pre-commssioning and
commissioning activities of the RKPP Project.

This Pre-Commissioning and Commissioning HSE Plan defines the safety precautions to be
established for ensuring that commissioning and start up activities are undertaken in a manner
that both personnel carrying out the works and personnel working in surrounded area will not be
exposed to hazard which may derive from these specific activities.

The HSE Plan describes the organisation, objectives, activities and schedule that SEPCOIII has
undertaken to manage the Health, Safety and Environment activities during the Project. An HSE
Management System has been established to ensure that all HSE issues are comprehensively
addressed during the Project cycle and that all project choices and decisions are justified with
respect to their implications on HSE.

The General Site Manager (GSM) will ensure that this document is regularly reviewed at site.

All parties will be informed of subsequent revisions.

Distribution of this HSE commissioning Plan shall be controlled by the Project Manager.

Distribution of this document will be to:

 Contractor Project Director

 Contractor General Site Manager;
 Contractor Commissioning Manager;
 Contractor Construction Manager;
 Contractor HSE Manager;
 O/E
 Subcontractors Site Managers;

This plan has to be read in conjunction with the HSE Plan (00-TAA-ADC-107001-00) especially
for the part relevant to the applicable laws, regulation and references.
This Plan is a live document and as such, will be developed by SEPCOIII, as necessary during
the project.

2. Project Description

The RAS AL KHAIR Power and Desalination Plant - Phase 1 (RAS-Phase-1) shall consist of a
combined cycle co-generation power and desalination plant having:
 2,400 MW net power output (1,050 MW supply to SEC + 1,350 MW supply to Ma’aden Aluminum
Complex)
 1,025 Tm³/d water productions (1,000 Tm³/d supply to SWCC + 25 Tm³/d supply to Ma’aden
Aluminum Complex).

The site of the RAS AL KHAIR Power and Desalination Plant is located along the shore of the
Arabian Gulf at RAS AL KHAIR, approximately 75 km northeast of Al Jubail. To the east and
west the site is bordering to Ma’adens new bauxite refinery and aluminum smelter. In the south
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the gas supply pipeline and the 380 kV Substation with the overhead lines will be arranged. In
the north is the Arabian Gulf and in the west will be the water pumping station and the
connection to the water, natural gas and the access road corridors. The site shall be extended to
the west to get sufficient space for the 6 power blocks and a direct connection to the designed
380 kV substation. The power plant blocks consisting of GT, ST, HRSG and auxiliaries,
including transformers shall be arranged in line next to the distillers in the central area from east
to west. Those components shall be combined to six mostly similar power blocks. Two simple
cycles GTs for back up is located at the west end of the power plant blocks. The black start
power supply is located south of the power plant blocks.

The central control building, the compressed air station and the central water chilling facility
(HVAC Building), central canteen and Mosque shall be located between RO Plant and Power
plant blocks. The power station electrical system shall be arranged next to the turbines.
Some electrical components like switchgear buildings or transformer units shall be arranged
locally next to their users. The gas station with corresponding gas handling facilities like
pressure reducing and boosting plant shall be arranged in the south-eastern area of the site.
The natural gas shall be delivered via pipeline, which will be routed along the southern fence.
The tank farm for back-up fuel shall be connected to the new fuel pipeline located at the south
east corner of the construction fence.

HSE Management on the project extends to all construction related operations and refers to filed
settings during the EPC execution of the project.

3. Definition and abbreviations

3.1 Definitions

Pre- Commissioning Means: The series of inspections and tests, generally static,
performed by the Contractor in accordance with the Contract to verify
the integrity, functionality and calibration of all components and the
systems forming part of the Work. The Pre- Commissioning begins
and the end of the Construction Phase and concludes at the
Mechanical Completion (Ready for Commissioning).

Mechanical Completion Means that:

a) all construction work and assembly of the Materials and
Equipment has been carried out in accordance with the
Contract;
b) the Work has passed all the tests (Pre- Commissioning)
that are to be passed prior to Mechanical Completion
pursuant to the terms of the Contract;
c) the Work is ready for commencement of the
Commissioning which is to be performed by the
Contractor to the satisfaction of the Contracting
Authority;
d) the documents have been delivered to the Contracting
Authority in accordance with the Contract.
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Commissioning Means: The dynamic running of the systems for further checking out
the functionality and integrity of complete systems, and continues on
from Pre- Commissioning. It is the last series of checks before
running the process systems on hydrocarbons.

Ready for Start-up Means: The successful completion of the system Commissioning in
accordance with the Contract and to the written satisfaction of the
O/E in order to allow the safe admission of process fluids and
hydrocarbons prior to Start-Up. The Ready for Start-up Certificate is
issued by the Contracting Authority to the Contractor in accordance
with the provisions of the Contract notifying the Contractor of the
Ready for Start-up.

Start-up Means: The actions, operations, development and testing performed

by the Contractor in accordance with the Contract between Ready for
Start-up and prior to commencement of the first Performance Tests.
Start-up commences with the introduction of process fluids, or
hydrocarbons, into the Permanent Works with the intent of starting
the plant production. It includes some tests (as leak tests, turbine
running, etc.) which need the introduction of hydrocarbons to be
performed.

3.2 Abbreviations

HSEM HSE Manager

HSE Health, Safety and Environment

MEDEVAC Medical Evacuation

PHSER Project Health Safety and Environmental Requirements

PPE Personal Protective Equipment

PTW Permit To Work

4. Reference

 Construction Environment Management Plan 00-TAA-ADC-107005-00

 Emergency Plan 00-TAA-ADC-107003-00
 Confined Space Procedure 00-TAA-ABG-107021-00
 LOTO procedure 00-TAA-ABG-107066-00
 Waste Management Procedure 00-TAA-ABG-107049-00
 Simultaneous operation 00-TAA-ABG-107057-00
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5. HSE responsibilities and organization

5.1 HSE Organization

A Project HSE Team has been appointed to perform all the activities included in this HSE Plan.
The Contractor’s Site HSE organization for Commissioning phase is shown on here below:
 General Site
Manager

Construction Commissioning HSE Manager

manager manager

PTW Coordination
HSE Comm HSE Comm
Coordinator Coord

HSE Comm HSE Comm

HSE Comm HSE Comm Sup Sup
Sup Sup

Mechanical Instrumentation Electrical

Coordinator coordinator Coordinator
5.2 HSE Function and Responsibilities

5.2.1 General Site Manager

The GSM shall:

 assume a leadership role in the HSE process;
 ensure that all line management and supervision conduct their duties in a
manner which supports the Zero Accident Tolerance philosophy;
 ensure that all site personnel are competent, qualified and adequately trained
to perform duties given to them during the course of the Commissioning phase;
 establish and maintain a direct line of communication with the HSE Manager;
 ensure sufficient resources are available to effectively manage HSE issues;
 ensure the provision of adequate fire prevention and protection measures and
equipment.
 appoint a person for the role of Permit Coordinator to be responsible for the
Permit to work.

5.2.2 Commissioning Manager (COM)

He supervises and coordinates the Commissioning activities at Sites, so as to ensure the compliance
with the established schedule, budget and project requirements.

The responsibilities include the following:

 Producing and updating detailed plans and procedures of the activities of his
competence and supervise that proper procedures are followed;
 Co-ordinating all parties present at Site, i.e. Subcontractor personnel, Vendors
specialists, Licensors personnel for the activities of his competence;
 Ensuring that the Project HSE requirements and Specific HSE issues related
to commissioning activities are considered.
 Co-operating with the HSE Manager for planning and carrying out
Occupational HSE Management for the Commissioning Team.
 Cooperating with the HSE Manager for implementing the Project HSE
Management System during the Commissioning phase. This includes:
identification of hazards; implementation of proper control measures, including
HSE training, planning of Emergency Preparedness and Response for the
Commissioning activities.
 Ensuring that all work is carried out under the controls of Permit to Work
System.

5.2.3 Discipline Commissioning Coordinators

He assists the Commissioning Manager in supervising and coordinating the Commissioning activities at
sites, so as to ensure the compliance with the established schedule and project requirements.

He therefore shares the responsibilities of the Commissioning Manager in matter of HSE.

5.2.4 HSE Manager

He will maintain the responsibilities indicated in the HSE Plan for Construction for the ongoing relevant
works.
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For the Pre-Commissioning, Commissioning, and start-up:

 He shall ensure that HSE Procedures are in place when required for a specific
activity, before the relevant work is started wherever at site.
 He shall verify, through the Commissioning HSE organization, that:
 Works are carried out by all personnel involved in a safe way, in accordance
with the applicable HSE Procedures, and with any special safety precaution
resulting from the job hazard analysis.
 No unsafe condition occurs during the execution of the works, and if any, work
is stopped, as necessary, until causes of the unsafe conditions are removed;
 Works are carried out with adequate, safety-compliant and approved tools,
machinery and systems, and all personnel involved has appropriate PPE as
required for the specific task and environment.
 He shall establish and maintain a professional relationship with the designated
Subcontractors and Vendors Representatives, to ensure that activities carried
out by them at Site are in full compliance with the provisions of this HSE Plan
and the applicable HSE Procedures and Safe Work Instructions, and with any
recommendations that could arise from Work Method Statement.
 He shall supervise preparation and execution of the Commissioning HSE
training program for involved Contractor and subcontractors personnel. This
will be in close coordination with the HSE Trainers.

5.2.5 HSE Commissioning Coordinator

The HSE Commissioning Coordinator reports to the HSE Managers, and shall

 updating of this document and verifying its correct implementation;

 promotion of the Zero Accident Tolerance Philosophy;
 management of the resources and HSE personnel required for the fulfilment of HSE
tasks in Commissioning phase;
 notifying the HSEM, of any HSE related incident/accident involving personnel,
equipment, property or environment;
 liaise with Subcontractor, suppliers and vendors on HSE issues, concerning
commissioning activities;

5.2.6 Commissioning HSE Supervisors

Commissioning Safety Officers shall ensure day-by-day compliance of the works with the applicable
HSE Procedures, Safe work instruction, and any specific HSE requirement.

5.3 Sub-Contractors personnel and Vendors Specialists

Sub-contractors personnel will be used during commissioning and plant operation for specific labours,
and employed under manpower hire basis.

Subcontractors’ personnel will perform the assigned tasks under the supervision and following instruction
given by the Commissioning /Operations Team.

Each Sub-contractor involved in Commissioning/Operation works shall provide adequately trained and
skilled personnel, as per the job positions specified in the Contractor request.
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Vendors’ specialists will advice and attend preparation, commissioning, tests and start-up of complex
machinery and package units.

This will be under the supervision of the Commissioning / Operations Contractor Team. They shall
perform their tasks safely, be equipped with adequate PPE, provide to the relevant Commissioning
Supervisor all safety information and advice relevant to the risk associated with their specific tasks.

Contractor Commissioning/Operation Team will have overall responsibility of the works performed by
vendors specialists.
Vendors’ specialists shall therefore:
 Conform to all work instruction given by the Contractor Commissioning/
Operation Supervisor.
 Follow the Contractor HSE Procedures and safe work practices.
 Comply with any safety instructions given to them by the Commissioning HSE
Coordinator or Safety Officer.

6. HSE objectives during pre-commissioning and commissioning

The Pre-Commissioning and Commissioning activities must be performed in full compliance with the
safety and environmental regulations and requirements:
The Project HSE Objectives during Pre-Commissioning and Commissioning are achieved by:
 Defining and maintaining an effective organization, plans and working practices
to manage the risk to all Site Personnel and minimize adverse effect to
environment;
 Setting HSE targets and monitoring HSE performance through statistical
indicators;
 Motivating personnel at all levels on HSE issues and communicating clear HSE
commitments:
 Identifying training requirements for the Pre-Commissioning and
Commissioning team and providing adequate training;
 Ensure that the health conditions in the workplace meet all the relevant laws
and standards;
The HSE performance during the Commissioning phase needs to be verified by:
 Ensuring emergency drills are carried out to evaluate the effectiveness of the
emergency plan;
 Monitoring that each activity is performed in accordance with the specified
procedures and with all control and recovery measures in place;
 Investigating incidents with the final objectives to prevent reoccurrence;
 Monitoring those environmental protection measures;

7. Pre-commissioning and commissioning activities

7.1 Pre-Commissioning

Pre- Commissioning consists in checking construction completion and carrying out static tests on all
items of the System/ Subsystem part of the new facilities.
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Pre- Commissioning leads to the Mechanical Completion of the Work and to the stage where the
System/ Subsystem is ready for dynamic testing (Commissioning).
All the detailed activities are specified in the Project Pre-Commissioning Manual.

Mechanical Completion marks the end of construction and Pre- Commissioning activities. It is achieved
when all inspection and testing to validate the completeness and correctness execution of construction,
are completed and documented.
Commissioning means the dynamic running of systems to further check out the functionality and integrity
of complete systems, and continues on from Pre-Commissioning. It is the last series of checks before
running the process systems on hydrocarbons. It includes the operation of the utilities systems to
progress the commissioning of process systems. All the detailed activity are specified in the Project
Commissioning Manual ( ).
Commissioning activities will start and be completed as early as possible in order to identify equipment
problems early enough to be rectified without impacting the project schedule.

8. HSE activites during commissioning phase

The Commissioning phase is a critical operation, with significant risk of causing major injuries, damaged
equipment and to the environment, have to be strictly monitored, the risks is increased due to the
occurrence of some, or all, of the factors listed below:
 Transition through temporary stages; Commissioning activities take place in
stages, with changing degrees of interconnection with existing, live
(hydrocarbon containing, energised) facilities.
 Existence of concurrent activities; some Commissioning activities may proceed
concurrently with, for example construction and production/maintenance
activities.

Contractor on the base of the HAZID (HAZard Identification) Report attached to this document
(attachement 1) has developed the HSE Procedures listed here below. Procedures shall provide general
HSE Requirements, and Risk Assessment to be followed during the activites.

· Pr1 : Air Blowing

· Pr2 : Equipment inspection and closure
· Pr3 : Chemical handling and first filling
· Pr4 : Water flushing
· Pr5 : Electrical testing
· Pr6: Lube oil and seal oil flushing
· Pr7: Uncoupled running motor test
· Pr8: Chemical cleaning
· Pr9: System inerting
· Pr10: Tightness test
· Pr11: Piping Dry out and preservation
· Pr13: Machine preparation for Start up
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· Pr14: Fire Heater preparation for Start up

Every time these Risks Assessment don’t cover the tasks or a particular activity is planned the
Commissioning Manager or his Deputy, for these critical activities shall prepare a specific Work Method
Statement where indicates:
 Description of the specific activity
 System involved
 Equipment to remove or install
 Chemical substances used
The HSE department jointly with the Commissioning team for each Work Method Statement shall
prepare the dedicated Risk Assessment in order to identify all the safety measures to be put in place
according to the HSE Procedures.

Additional Task Risk Assessment has been carried out for the activities of:

 Lifting Opeation
 Scaffolding erection
 Working at height

These risk assessment (attachment 2) shall be applied in conjunction with other risk assessment each
time shall be applicable for the task to be carried out.

According to the schedule other WMS shall be prepared for critical activities.
Here below is reported the form to be used for carry out the Risk Assessment activity.
EVENT RISK SCREENING MATRIX:
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RISK ASSESSMENT

DATE PREPARED BY
ACTIVITY ANALIZED CHECKED BY
SUPERVISOR SIGNATURE

N° ACTIVITY HAZARD HAZARD EFFECT RISK CONTROL MEASURES RESIDUAL RESPONSIBLE

DESCRIPTION VALUE RISK
R=SxL

Note:
8.1 HSE Training
The Contractor HSE Manager, through his staff, shall provide HSE introduction to all personnel assigned
to Commissioning activities. All personnel shall receive the following training:

Commissioning Induction Training

Commissioning PTW System

The Commissioning Manager shall advice on any specific HSE training requirements for personnel
involved in the Commissioning activities.

8.2 HSE Meetings

SEPCOIII will establish a Project specific program for HSE meetings at all levels within theirs and
Subcontractor’s organizations to:
 Communicate HSE commitments and requirements;
 Achieve full involvement of all workforces in HSE issues.

The following HSE meetings are to be held during the Commissioning phase:

Meetings Frequency Attendance

Coordination Meetings Weekly Commissioning Manager
HSE Manager
Subcontractors Representatives
(Commissioning Manager, HSE manager)
Vendor (if required)
Client Representative
PTW Meetings Every time Discipline Commissioning Coordinator
start a new Commissioning HSE Coordinator
task (daily) PTW Coordiantor
Subcontractors involved

In addition, task specific HSE meetings and toolbox meetings with subcontractor work force will be held
before each critical task is performed.

8.3 Emergency Response Planning

These plans comprehensively address actions, tasks and responsibilities required for the appropriate
management of any emergency arising in the work areas at site.
The Emergency Response Plan developed during Construction activities (00-TAA-ADC-107003-00) shall
be used for all contact numbers, roles and responsibilities and references.
The communication ways are:

 Radio Motorola (GPSA)

 Thuraya Mobile
 Mobile telephone (GSM)
 Fix telephone line (CISCO System)

Fire fighting shall be managed using pump connected with a water truck that will be positioned on the
surrounding of the commissioning activities and with sufficient portable fire extinguisher.
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A trained fire team will be available on a 24-hrs per day basis at each energised substation until such
times as the F&G System is commissioned.

Fire fighting shall be managed using fire fighting truck that will be positioned on the surrounding of the
commissioning activities.

8.3.1 Emergency Response Drills

The emergency response plans are drilled at least once during Commissioning phase to verify and
improve their effectiveness and personnel are trained in its use. The emergency drills shall be fully
documented and if necessary, followed-up by a review.

8.4 Work Permit System

The Permit to Work system is designed to ensure that a safe environment is achieved by providing
management control over the various work activities, which may be potentially hazardous and has to be
monitored.

During Commissioning activities shall be used the system referred in the document (Permit to work 00-
TAA-ABG-107067-00) that is jointly prepared with CA.
For all the construction activities to be carried out inside areas Under Commissioning Authority shall be
applied the commissioning PTW System.

During this phase all the Construction activities to be performed in areas under Construction Authority
the PTW Procedure (MLEG-00-AP-X-75OO22-24) remains in place for governing the relevant activities.

Here below is reported the flow chart that shall be followed for the PTW to be applied during
commissioning activities.
 5
1 3
NP
NP 2 4
Originator
Performing Authority

CC

1 CLIENT AUTHORITY
NP

PTW COORDINATOR
OFFICE
NP 5
1 3
NP
2 4

1
NP
MEETING:
2
PT W C OORDINATOR
ISSUING AUTHORIT Y (3) AREA AUTHORITY
HSE FUNC TIO N (0)
AREA AU TOR YTY (2)

1 3
NP CC
2
HSE FUNCTION

INSPECTION AT SITE B Y
HSE FUNCTION & PERSO N
RESPONSIB LE AREA

PERSON
RESPONSIBLE FOR
AREA CC
Coordination meeting work flow

COORDINATION
MEETING

PERFORMING/ISS
UING AUTHORITY

ALL DOCS
REQUIRED ARE JOB
PRESENT IDENTIFICATION
N
TASK RISK
ASSESSMENT
Y

CHECK LIST
INSPECTION AT
SITE

CONTROL
MEASURES PUT
IN PLACE

PTW SIGNED
N
Y Additional
GAS TEST Gas
Perform gas preacaution
REQUIRED? free?
test

N
Y
PRA &PTW signature
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8.5 Site Access and Security Procedure

During the Commissioning phase the RKPP area will become a “live plant” area processing
Hydrocarbons, and therefore the presence of people and vehicles shall be limited as much as possible.

Access Control
The RKPP plant shall be fenced and gates shall be provided and each of these shall be provided with a
main gate for control of vehicles access and a pedestrian gate for working team members. A control is
provided and will be manned on a 24 hrs shift basis by Security Personnel.
A Muster Point shall be identified close to each gate emergency evacuation.

8.6 Lock Out and Tag Out Procedure

The purpose of the LO/TO Procedure is to define minimum requirements for isolation, lockout and use of
tags during the Pre-Commissioning and Commissioning phases.
The procedure shall be applied by all personnel working under SEPCOIII Commissioning Team
responsibility in all situations where equipment may be damaged or personnel may be injured due to an
unexpected release of energy or hazardous materials. Source of energy include mechanical, hydraulic
and pneumatic and energy system

8.7 System Isolation

System or sub system could be required to be isolated by the need/necessity decided by the
Commissioning team. Isolation can be done either by closing valves or by temporary/ permanent spades.
Dedicated register has to be in place to record the isolation item utilised and copy of the P&ID involved
attached. The item used for the isolation has to have a card tag “DO NOT OPERATE” and temporary
item has to be red spray painted.

8.8 Job safety analysis

The results of the Job Safety Analysis will be used to enhance the safety of the operations by improving
both on operational philosophy and on the preparedness to face the predictable incidents, and will be
attached to the PTW in case the activity is not cover by Work Method Statement or Risk Assessment

8.8.1 Personnel Protective Equipment

All personnel working in the field shall wear as a minimum the basic Personal Protective Equipment.

Contractor and Subcontractor Site HSE Managers shall ensure that the quality and quantity of PPE is as
per Standards actually in force.

Any special PPE requirement for a specific Commissioning work shall be specified in the Permit to Wok
form, also with regard to the recommendation for handling any chemicals to be used, as per the relevant
MSDS

8.9 Chemical Handling and MSDS

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When dealing with a potentially harmful chemical, precautions should be taken to ensure that employees
do not swallow it, inhale it, or allow it to contact their skin. The chemical must not be allowed to
accidentally mix with other substances in transportation, storage, or use. It must not be subjected to
undue shock, pressure, or heat. When the chemical is no longer needed, it must be safely disposed of
or recycled.

When dealing with an unfamiliar chemical, it is always wise to assume that it is hazardous. The
exposure to hazards associated with a material depends largely on its proper identification, handling,
usage, transport, storage and disposal. Only the necessary amount of hazardous materials should be
brought into the site. Hazardous materials must not be allowed to accumulate, and any extra amounts
should be cleared from the work area. Slop liquids or trash should be cleared away immediately. All
hazardous materials should be stored according to the specifications of their Material Safety Data
Sheets (MSDS).

8.10 Accident Investigation, Reporting and Follow-up

The Accident Reporting and Investigation Procedure in place for the Construction activities (00-TAA-
ABG-107007-00) shall be used for reporting, investigation and follow-up of incidents during
Commissioning phase.

The objectives are:

 To investigate all hazardous incidents to find out root and contingency causes
which determine the occurrence;
 To disseminate learning points to all appropriate personnel and groups
 To take corrective actions and monitor their implementation.

The overall objective is to prevent reoccurrence of similar incidents.

8.11 Health
8.11.1 Health and Hygiene Plan

The health and Hygiene plan is the key reference tool within the Contractor to ensure that employees’
health is properly assessed, monitored, safeguarded and managed.
It defines the general criteria and the responsibilities of Contractor and Medical department; to define
and put into effect organizational and operational regulations governing the project medical service. That
is to support Contractor’s mission and implement management policies regarding employees’ health.

The health and Hygiene plan covers the following aspects:

o Medical service organizations
o Healthcare prevention program in the worksite
o Health education and training
o Hygiene surveillance
o Data registration, reports elaboration
o Use and abuse of drugs and alcohol prevention and management
o Medical waste
o Audit
8.11.2 Hygiene and Sanitation
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Contractor’s site offices and other temporary facilities are provided with facilities to ensure that good
hygiene and sanitation at these facilities. Garbage and waste will be collected by Contractor and
disposed of into authorized area out of site as per Project Waste Management Plan.

8.12 Environment
This section describes the activities aimed at ensuring that the potential environmental impacts during
the Commissioning activities are maintained within acceptable limits.
The essential objectives are as follows:
 Identify potential environmental impacts;
 Identify mitigation measures to control adverse effects
 Plan activities of control, monitoring, auditing, inspections and corrective
actions to ensure compliance with the project environmental requirements.

The objectives are accomplished during the Commissioning phase by means of the following activities:

8.12.1 Waste Management

Contractor shall implement waste disposal as required by the Contract and local laws and regulations, as
per the Waste Management Procedure 00-TAA-ABG-107049-00.
The objectives of the Waste management activities are:
 To ensure the responsible and safe disposal of wastes as defined by the
Waste Management Plan.
 To reduce the volumes of hazardous and non-hazardous waste generated
during the Commissioning phase.

The following types of waste will be managed during the Commissioning activities:
 Aqueous waste
 Non-hazardous waste (solid and liquid of domestic and industrial origin)
 Hazardous waste (solid and liquid; comprising of spent oils, grease and
chemicals etc.)
 Gaseous waste (particulate)

The above types of wastes shall be properly separated and disposed of according to waste disposal
requirements.

8.12.2 Noise

Any Commissioning operations likely to produce high noise levels will be planned, whenever possible, to
take place in periods with lowest impact to personnel in the vicinity and adequate PPE will be provided to
those involved in the activity.

8.13 HSE Inspection and Monitoring

The Contractor’s Field HSE Manager shall ensure that daily inspection is carried out to:
 Monitor Commissioning activities for ensuring that the HSE requirements are
being complied with;
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 Identify hazards and ensure that safe working procedures are developed to
deal with them;
 Report negative aspects, if any, of the items promptly in writing to Site
Manager and Commissioning Manager and to ensure the follow-up action.

The Field HSE Manager may perform other inspections on:

 Immediately dangerous or hazardous conditions.
 Accident, incident or near miss conditions.

8.13.1 Safety Area Conditions Inspection

Daily inspection shall be carried out in order to check in all HSE requirement and measures are put in
place for the activity to be done.
The check list attached to each procedure shall be used and attached to the relevant PTW.

8.14 SIMOPS
The SIMOPS (Simultaneous operation procedure 00-TAA-ABG-107057-00) study is able to identify
potential hazards due to possible interferences between typical activities (and/or “non-routine activities”)
with“surrounding environment” in order to reduce the related risks to an ALARP level. At this scope the
SIMOPS study will be carried out on site during commissioning operations by the site personnel

8.15 HAZID report

HAZID report tool identified for each commissioning activity the general control measures to be put in
place, this has to be considered a live document to be reviewed each time is required
Attachment 1 Hazid report

HAZID REPORT
Commissioning Operations
Operation Potential Hazard Consequences Risk Mitigations Risk Comments

Commissioning HSE - Uncompleted or - Delay of the - Competent persons shall prepare For the activities not
documentations missing commissioning the safety operating procedures and covered by the HSE
documentation. activities. safety documentation to optimize the Commissioning Plan a
commissioning operations. new procedures / risk
M L
- Failure to follow - Continuous assessments shall be
operating procedures hazardous situation issued and used after
or safety rules. their approval
- Adverse publicity

Commissioning - Unplanned activity - Injury/fatality to - Planned Activities issued 24 hrs. in

activities: personnel advance.
- Human error
- Spade/blinds - Damage to H - Competent and trained personnel
insertion to isolate -Failure to follow equipment with direct supervision. L
section of pipes, operating procedures
pumps, vessels of the or safety rules - Fire/Explosion - Personnel shall be familiarizing with
process unit commissioning/safety operating
- PTW and - Delays of procedures.
- Air blowing mechanical/electrical commissioning
List of authorized
isolation system not operations - Daily permit to work meeting, good
personnel to sign the
- High pressure followed unauthorized knowledge of PTW &
PTW shall be posted
testing up to operate work. mechanical/electrical Isolation
pressure certificates system on place, work
area inspection and risk assessment PTW training to all
- Testing equipment
as required. involved personnel
- High water flushing not fit for the purpose.

- Nitrogen purging - High pressure - Spading/blinding list and marked

release and drawing to fit spades and blinds.
disengaging of Register shall be follow-up and kept
- Chemicals cleaning continuously updated by accountable
fasteners during leak
testing supervisor.
- Loss of containment Toolbox Talk to all involved
structural failure personnel.
incorrect assembly
seal or packing failure - Nitrogen flushing to eliminate Ox
contents from pipes, vessels, to
- Failure to follow maintain pipes, vessel, utilities and
spade/blinds insertion common part inerted before gas in.
procedure, P&I not
updated - Use of certified equipment,
calibrated gauges correctly rated and
- Handling chemicals in good working condition
without MSDS
unknown maximum - Barrier off the zone as per the
exposure limit & pressure test rating & warning signs
concentration of an posted to all around the work testing
airborne substance. area to prevent non-essential
(MEL/OES) personnel entering the area.
Exposure route of Especially around the pressure
hazardous substance pumping equipment.
as follow: Inhalation,
Ingestion, Skin
- Installed bolts tightened by specialist
absorption, Injection.
personnel, torque level sufficient to
Chemicals spill prevent leakage. Use of proper PPE.
Environmental effects Isolate and depressurize the
Slips, trips & fall equipment before start the job.
Fire Depressurize whole line
Car accident
- Personnel shall be aware on MSDS
Prior chemicals handling, wearing of Chemicals register shall
chemical protective clothing shall be be implemented.
suitable for all the types of chemicals
being handling; goggles, face mask,
gloves and apron. Implement Site Work
Toolbox Talk to be conducted, the Instruction for chemical
personnel at risk exposure must be handling
made aware of the risks and
precautions to be taken.
The spills must be contained; don’t
touch or walk through the spilled
material, avoid to breathing vapors,
use only inert non-combustible
 absorbent

Only authorized vehicles can enter at

CPF.
Electrical Systems Electrical shock Personnel PTW and Electrical Isolation
(low and high voltage) injury/fatality, Certificate issued. Tool Box Talks
equipment damaged performed. Only authorized personnel L
shall be used. Follow the procedure
M
for low and high voltage. Use of
properly PPE is required.
Instrumentation Instrument devices Personnel injury, Pre-inspection, calibration test,
failure equipment damaged spares available, instrument have
M isolation valves for changeover, L
continuous monitoring
Hand and power tools Homemade hand tools Personnel injury, Regularly inspection of equipment, L
equipment damaged power supply and cables carry
M out. Only competent personnel shall
be used. Properly PPE is required.
Follow-up the procedure.
Working at height Fall from height Personnel PTW, Toolbox Talk to all personnel
Falling objects injury/fatality involved.
Hit by Safe access and egress
Slips and trips H Competent and trained personnel L
Collapse of scaffold may perform the job. Safety harness
connected by life line.
Fire
Certified equipment/basket.
Heat stress
Certified scaffold. Do not steep on top
Phobia
the structure.
Good working platform (Toe board &
boards without gaps) Fire
precautions.
Good housekeeping.
Barrier off. Signs, precaution falling
objects.
Job rotation during heat exposure
Direct supervision/Correct PPE
Crane lifting Crane failure Injury of personnel A certified crane will be used for the
operations Fall of lifted objects Damage of equipment purpose. Lifting plan.
Lifting accessories Operational delays Method statement shall be in place
failure. Contact with H identifying all the lifting equipment to L
overhead power lines be used.
Strike against adjacent Ensure crane maintenance schedule
structures is up to date.
Human error Ensure radio contact between banks
man and crane operator is
maintained.
Qualified crane operator and rigger.
Use of certified lifting and rigging
equipment with appropriate colour
coding.
Lifting gears and appliances to be
inspected prior to commence the work
by competent person.
Use of international hand signal.
Do not exceed SWL.
No working under suspended load.
Use of the tag lines.
Barrier off the area to keep non-
essential persons away.
Human error Warning signs posted.
Delay of the plant
Start-up gas in: High pressure handover
Function failure of Daily routine inspection shall be
H carried out by competent well L
wellhead control panel
-Well Start-up/Shut-in Financial impacts due operator.
Loss of well control to:
-Well flow line, Periodic functionality check of
manifold monitoring Operational downtime wellhead control panel.
Flow line rupture, Repair costs,
Failure of valves Preventive maintenance of all valves
Additional gauges.
equipment/material to
Failure to follow be purchased,
operating procedure or Flow lines manifold visual inspection
safety rules shall be continuously done by
necessity or additional competent persons.
Lack of designing, re-
communications Lack To align the new manifold gas leak
engineering, monitoring.
of data Constant radio communications to be
Failure of Fire & Gas established and maintained between
detection. site work parties and CCR
Operating out of
design parameters Competent personnel in place having
Failure of electrical a good experience of Start-up
system. activities.
Toll box talk, task risk assessments
are carried out and agreed measures
implemented.
Operating manuals and procedures in
place.
Strict adherence to procedures at all
times.
Align the valves as final configuration
before hydrocarbon flow, to perform
the gas leak test up to operating
pressure.
Wear mandatory PPE, personal gas
detector escape set.
B.A. sets at location as required
Fire & Gas system fully operational.
Periodic checks of instrument are
carried out and recorded.
Continuous gas monitoring of pipe
joints by HSE Supervisor/Officers.

Constant radio communications to be

established and maintained between
site work parties and CCR
Radio sets testing, spare battery
available to all involved personnel.
Preventive maintenance team stand
by at location.
Emergency Response Plan fully
operational.
Fire truck and Fire Fighting Team
stand by at location.
 Fire water line testing and checks all
emergency equipment at location.
First Aid team stand by,
Medevac procedure in place.
Design review / HAZOP performed
(during design phase)
DCS fully functional.
Document control system in place.
Plant operating Human error Gas release Regular training and testing of Gas basic training to all
personnel Environmental effect personnel, and systematic follow-up operators
High pressure to assure that operating procedures
are followed.
Function failure of H L
equipment control
panel
Loss of control
Fire/Explosion people
injuries or Fatalities
Equipment and
structures damage
etc.
Power distribution & Total black-out (2 lines Injury/fatality of Emergency power generation start- Planned check lists and
Emergency power 60 KV on transformers personnel up, in order to feed all the emergency maintenance register
generation 60/5.5 KV). Fire loads, including F.F., control cabinets
Plant shutdown UPS for ESD/DCS/PDCS/F&G, plant
H L
Human errors monitoring system, and utilities.
/incompetent On the transition time between the
personnel main shutdown and the Emergency
Loss power generation power generation, control cabinets
UPS shall feed the control system.
Daily and night inspection carried out
by on duty personnel.
Formal vendor training completed.
Periodical checks to emergency
generator and battery room.
PTW & isolation procedure and
registers full implemented.
Rescue kit equipment and CO2 fire
extinguishers at location; electrical
 substations.
Warning safety signs and safety
notice posted.
Day/night safety inspection.
Mandatory PPE
Utilities Human errors Gas release Daily monitoring and visual inspection
Loss air instruments Environmental effect carried out by competent person; N2
control and services Fire/Explosion package, air package, etc…….
Procedures not Injury/fatality H Check lists L
followed Equipment damage Periodical maintenance: record and
Noncompliance/ register.
deviation from design Implementation of operating
parameters procedures
Lack of inspection / Formal vendor training to all
Poor maintenance personnel.
Lack or miss Correct PPE
interpretation of
Operating procedure
Fire fighting Missing planned Uncontrolled fire Approved safety plan at location
equipment maintenance activities situation Inventory of all emergency equipment
Unplanned inspection Injury/fatality of the to maintain updated.
of equipment. personnel H Planned maintenance program. To L
Safety plan not in carry out periodical inspection and
place. services as required of; BA sets, fire
Missing equipment hoses, fire extinguishers, checks
water and foam tank level, avoid
water leak , emergency fire pumps,
fire water line testing, to move
water/foam monitors, emergency
warning lights, alarms testing,
personnel training to familiarize with
equipment etc…
Equipment certificate/conformity.
Exposure of high Health effect injury Health effect injury Admittance to areas of high noise
noise during routine and illness and illness exposure is to be denied to persons
inspection not equipped with ear protection.
M Noise levels shall be posted on L
entrance to noisy areas with exposure
 up to 90dB along with mandatory
signs for wearing hearing protection.
Health surveillance carried out at
pre-defined intervals.
Emergency Emergency response Uncontrolled Emergency Response Plan in place ERP training programs
handling plan not in place. fire/rescue situation clear identified role and responsibility. shall be planned.
Inadequate response Panic, missing Emergency flow chart.
from personnel to personnel H Emergency contact numbers. M Routine emergency
emergency situations. Injury/fatality of the Fire-fighting organization and exercises to be
personnel equipment. conducted on a periodic
Adverse publicity Medevac procedures. base (monthly
Equipment damage schedule).
Emergency drills schedule; fire, gas
release, muster & evacuation, first aid
and medevac.
Corrective Compromise integrity Uncontrolled gas Operation procedures for start-up and
maintenance to repair of the process release that can lead operation must be followed and the
or replace equipment potentially initiates to explosion with H integrity of vessels and pipes and the L
“instruments” while ESD or gas can be secondary jet flame. safety equipment must not exceed
lines are under released due to their design
pressure or defective valves not
commissioned. sealing.

Removing blinds to Blinds not replaced Gas release explosion It mandatory to reinstall the blinds To maintain updated the
connect temporary and valves not closed with secondary jet after purging activities was performed blind/spade register
hoses for purging properly flame H L
activities

Attachment 2 General risks assessment
EVENT RISK SCREENING MATRIX:
 RISK ASSESSMENT

DATE PREPARED BY
ACTIVITY ANALIZED Lifting operations CHECKED BY
SUPERVISOR SIGNATURE

N° ACTIVITY HAZARD HAZARD EFFECT RISK CONTROL MEASURES RESIDUAL RESPONSIBLE

DESCRIPTION VALUE RISK
R=SxL
1 Crane lifting Crane failure Injury / fatality 4 D H A certified crane will be 2 B L
operations Fall of lifted Equipment damage used for the purpose.
objects Lifting plan.
Lifting PTW, Method statement
accessories shall be in place identifying
failure all the lifting equipment to
Contact with be used.
overhead power Ensure crane maintenance
lines schedule is up to date.
Damage to Qualified crane operator
underground and rigger.
facilities Use of certified lifting and
Strike against rigging equipment with
adjacent appropriate colour coding.
structures Lifting gears and
Equipment appliances to be inspected
damage prior to commence the
Crushing injuries work by competent person.
to personnel Use of international hand
between loads signal.
and fixed plant Do not exceed SWL.
No working under
 suspended load.
Use of the tag lines.
The work area shall be
barrier off and signs
erected to prevent access
to other personnel.
Verification of underground
services.
Good working surfaces.
Monitor the weather limit
conditions.
Ensure direct and
competent supervision is in
place at all the times
during the entire lifting
operations.
Area inspection prior to
commence the lifting
operations.
Correct PPE
2 Communications Lack/lost radio 4 D H Define communication 2 B L
Communication before performing the lift.
between crane Competent personnel only
driver/banks man to operate crane with the
and lifting aid of a banks man at all
supervisor. times.
Follow procedures for
operating cranes at all
times.
Ensure banks man is in
control of the lifting
operations.
To avoid swinging
movement of the load
during the entire lifting
 operations.
Ensure radio contact
between banks man and
crane operator is
maintained.
Ensure direct and
competent supervision is in
place at all the times
during the entire lifting
operations.
Communication between
work parties; Crane
operator, banks man, lifting
supervisor must be kept
continuously in case any
emergency arise.
All involved personnel will
ensure radio
communication and will
check radio set and battery
prior to commence the
operations.
Spare batteries shall be
available.
Correct PPE
Direct supervision.
Toolbox Talk.

Note:
Scaffolding erection

RISK ASSESSMENT

DATE PREPARED BY
ACTIVITY ANALIZED Scaffold erection, dismantle. CHECKED BY
Access and Egress
SUPERVISOR SIGNATURE

N° ACTIVITY HAZARD HAZARD EFFECT RISK CONTROL MEASURES RESIDUAL RESPONSIBLE

DESCRIPTION VALUE RISK
R=SxL
Scaffold erection, Fall from height Injury / fatality to 4 D H PTW, approved procedure 3 A L
dismantle. Access (People) personnel in place. Tool Box Talk to
and Egress Fall from height all involved personnel
(Materials
Slips, Trips & fall Erection of scaffold must
hazards be carried out only by
Access/egress. competent personnel with
Incorrectly continuous supervision
constructed (following the standard
scaffold procedures).
Authorized use of
incomplete Adequate precautions from
scaffold fall hazard; safety
Lack of harnesses with fall
supervision absorber device (laynard)
connected to safety line,
ensure safety line well
fasted to the consolidate
structures and made free
fall from any obstruction.
Correct PPE. Direct
supervision.
The work area shall be
barrier off and signs
erected to prevent access
to other personnel.

Basket material use for

transferring tools…etc.

Working platform and work

area to be maintained to a
good order with toe board
and boards without any
gaps. Warning signs -
Caution Scaffold in
progress to be used during
erection.
Daily inspection carried out
by competent Supervisor.
Scaff-tag shall be posted
after the inspection.

Safe access and egress

points shall be granted at
all the time without any
obstruction.
Do not steep on top the
structure. Surfaces shall
be free from any holes,
slop and obstruction,
uneven or slippery.
Working at height
RISK ASSESSMENT

DATE PREPARED BY
ACTIVITY ANALIZED Working at height CHECKED BY
SUPERVISOR SIGNATURE

N° ACTIVITY HAZARD HAZARD EFFECT RISK VALUE CONTROL MEASURES RESIDUAL RESPONSIBL
DESCRIPTION R=SxL RISK E
1 Working at height Fall from height. Injury / fatality Safe access and egress.
Falling objects. Competent and trained personnel
Hit by, may perform the job.
Slips and trips. Safety harness connected by
Collapse of safety line.
scaffold Certified equipment and basket.
Fire Certified scaffold; daily inspection
Heat stress and scafftag posted.
Phobia Good working platform (Toe
board & boards without any gaps)
Do not steep on top the structure.
Fire precautions.
Good housekeeping.
Exclusive zone, barrier off
Signs, precaution falling objects.
Job rotation during heat
exposure.
Standby man, direct supervision,
corrects PPE.

Note: