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HSE Commissioning Standards PDF
HSE Commissioning Standards PDF
HSE STANDARDS
COMMISSIONING
Effective Date: 06/16/11 Standard: 14.6 Document Number: KUCSH0053 Rev: 01
14.6.1 INTRODUCTION
14.6.1.1 The purpose of this standard is to achieve a safe and effective transition
of assets from the construction, installation, or major repair phase to
owner custody while ensuring that benefits of the design objectives and
expectations are achieved for the company. This standard is not
intended to be a detailed commissioning plan for a given application but
rather a high level view of how a commissioning plan is developed and
the key elements which need to be included in the plan from the Safety
and Health perspective.
14.6.2 DEFINITIONS
14.6.2.1 Area Manager - Any one of the operating unit management team
members who have responsibility for accepting the asset – Operations
Manager, Maintenance Manager, General Manager.
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KUFM00076
KENNECOTT UTAH COPPER
HSE STANDARDS
COMMISSIONING
Effective Date: 06/16/11 Standard: 14.6 Document Number: KUCSH0053 Rev: 01
14.6.2.7 Custody Tagging: A process to transfer of Care, Custody and Control for
each phase of test work executed during the commissioning process
stating who is in control of the equipment during the three phases of
ownership. (See Exhibit 14.6.2)
14.6.2.8 Heavy Mobile Equipment (HME): Large mobile mining equipment – i.e.
haul trucks, shovels, drills, support equipment.
14.6.2.14 Project Manager: Person who is accountable for project execution and
project delivery to the Operating Unit.
14.6.3 SCOPE
©Kennecott Utah Copper. The standards on the KUC Intranet website are considered the standard in effect and
supersede all other revisions.
KUFM00076
KENNECOTT UTAH COPPER
HSE STANDARDS
COMMISSIONING
Effective Date: 06/16/11 Standard: 14.6 Document Number: KUCSH0053 Rev: 01
o Capital projects
o Major equipment assembly (new)
o Significant changes to operating facilities
o Restarting a mothballed process
o Post-turnaround start-up
o Start-up after major maintenance activity/rebuilds
NOTE: Commissioning can fall under the jurisdiction of either the Project
Manager or the Operating Unit depending on the application and needs
to be determined by the Project/Area Manager. Typically commissioning
planning and execution will also include vendor support.
14.6.4 REQUIREMENTS
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supersede all other revisions.
KUFM00076
KENNECOTT UTAH COPPER
HSE STANDARDS
COMMISSIONING
Effective Date: 06/16/11 Standard: 14.6 Document Number: KUCSH0053 Rev: 01
Page 4 of 20 Plant:
PRINTED COPIES ARE UNCONTROLLED
©Kennecott Utah Copper. The standards on the KUC Intranet website are considered the standard in effect and
supersede all other revisions.
KUFM00076
KENNECOTT UTAH COPPER
HSE STANDARDS
COMMISSIONING
Effective Date: 06/16/11 Standard: 14.6 Document Number: KUCSH0053 Rev: 01
REFERENCES
REVISION HISTORY
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KUFM00076
Exhibit 14.6.1: Commissioning Process Flow Diagram
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KUFM00076
Exhibit 14.6.2: Transfer of Care, Custody, and Control (Custody Tagging)
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KUFM00076
Examples of the custody tags:
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KUFM00076
Exhibit 14.6.3: Sample Pre-Startup Safety Review Checklist
Review Date:
Department / Area:
Process / Equipment:
MOC Number:
Sign below to indicate acceptance that the equipment or project is safe and satisfactory to startup with the
exception of the noted constraining action items.
Environmental Date
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KUFM00076
Constraining Action Items – Items to be completed BEFORE authorization and startup
Sign below only when all constraining action items are completed.
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
1.1 MACHINERY / EQUIPMENT SAFETY
Has the machinery/equipment been installed so that it will be stable and secure
1.1.1
during operation?
Have all vendor and company installation/assembly checklists been completed and
1.1.2
accepted, including Heavy Mobile Equipment (HME) and other equipment?
1.1.3 Are points of isolation clearly marked / labeled and readily accessible?
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
2.5.6.j Emergency alarm and communication system?
2.5.6.k Monitoring devices and sensors?
2.5.6.l Pumps?
2.5.6.m Lifting equipment?
Has a reliability engineering analysis been considered / completed for process
2.5.7
safety critical equipment?
Are certificates on file for any equipment tested by an outside organization (e.g.,
2.5.8
pressure vessels, pressure relief devices, lifting equipment, etc.)?
Have all commissioning tests or inspections been identified and completed (e.g.,
2.5.9
pressure tests, leak tests, passivating procedures, etc.)?
2.5.10 Has Custody Tagging been completed?
2.5.11 Have dry and cold testing been completed?
2.5.12 Have hot and wet testing been completed? (prior to the introduction of chemicals)
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
3.0 ENVIRONMENTAL
Are all secondary containment facilities adequate including the unloading areas for
3.1
bulk liquid chemicals (110% of truck volume)?
3.2 Are all material storage facilities adequate and appropriately labeled?
Have adequate arrangements been made, prior to start-up, for the identification,
3.3
classification and safe disposal of all waste materials?
Have all materials used in the system been entered on an area chemicals inventory
3.4
list (or equivalent)?
3.5 Are updated area spill procedures available?
Are material unloading facilities adequate and constructed in accordance with
3.6
corporate safety, health, and environmental standards?
Have the corporate environmental guidelines been followed during the design stage
3.7
of this project?
3.8 Have all waste streams been identified, quantified, analyzed and minimized?
Are all of the applicable construction, environmental and operating permits up-to-
3.9
date and approved?
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
Have Emergency Response, medical, fire, HazMat, and other agencies been
4.7
included in emergency and incident response planning?
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KUFM00076
Exhibit 14.6.4: Sample Field Walkthrough Checklist
Review Date:
Department / Area:
Process / Equipment:
MOC Number:
Sign below to indicate acceptance that the equipment or project is safe and satisfactory to startup with the
exception of the noted constraining action items.
Operations Date
Environmental Date
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KUFM00076
Constraining Action Items – Items to be completed BEFORE authorization and startup
Sign below only when all constraining action items are completed.
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
1.1 MACHINERY / EQUIPMENT SAFETY
Has the machinery/equipment been installed so that it will be stable and secure
1.1.1
during operation?
Has all access to dangerous moving parts or danger zones created by the
1.1.2 equipment been prevented by the provision of the correct guards, interlocks and/or
barriers?
Have the correct safety measures been taken to prevent any risk from ejection of
1.1.3
material, failure of parts and their ejection, overheating or fire?
Has safe access been provided to the equipment for normal operations,
1.1.4
adjustments, service, calibration, maintenance, or repair?
Is the equipment provided with the properly identified START/STOP and
1.1.5 EMERGENCY controls that are positioned for safe operation without hesitation, loss
of time and without ambiguity?
Is the equipment provided with a clearly identified means to securely isolate it from
1.1.6
ALL energy sources?
1.1.7 Are points of isolation clearly marked / labeled and readily accessible?
1.2 ERGONOMICS
Have the workstations or equipment been constructed so that need for stooping,
1.2.1 bending, stretching, over-reaching and working over-head during operation has
been eliminated or minimized?
Has the need to lift, carry, push or pull heavy loads, or parts, been eliminated to the
1.2.2
extent possible?
Are all displays, screens, dials and START/STOP/ EMERGENCY buttons positioned
1.2.3
so that they are readily visible and accessible by the operating personnel?
Have displays and screens been positioned so that interference from glare is
1.2.4
reduced to the minimum?
Have workstations been designed and equipped so that the operator can adopt a
1.2.5
comfortable position?
1.2.6 Does the operation of this equipment increase the risk of upper limb disorders?
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
2.2 QUALITY ASSURANCE
Based on a field check as part of this PSSR, does the construction meet the design
2.2.1
specifications and match the engineering drawings?
3.0 ENVIRONMENTAL
Are all secondary containment facilities adequate including the unloading areas for
3.1
bulk liquid chemicals (110% of truck volume)?
3.2 Are all material storage facilities adequate and appropriately labeled?
Are material unloading facilities adequate and constructed in accordance with
3.2
corporate safety, health, and environmental standards?
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KUFM00076
PSSR ITEM CATEGORY / ITEM TO ASSESS YES / NO / NA
NO.
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KUFM00076