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CNPC International
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table of Contents
2. Relevant Documents
2.1 CNPC Corporate Standards
Q/SY 1245—2009 Specification for Pre-startup Safety Review Management
2.2 CNPCI Corporate HSE Management System
HSE – 2.0 HSE Management System Manual
HSE – 6.8 Procedure for Process and Mechanical Change Management
HSE – 4.9 Procedure for Process Hazard Analysis Management
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Deficiencies which are identified in the PSSR to be deviated from the design or operating
codes and/or standards, won’t hamper safe start-up of processes and equipment, but may have
negative impact on start-up efficiency and product quality and result in safety and/or
environmental accidents during operation, and could be corrected after start-up.
3.4 Area or Unit Chief
A manager responsible for the operation safety of the process or equipment to be started, such
as the head of a plant.
4. Responsibilities
4.1 Corporate HSE Department of CNPCI is responsible for formulation, management and
maintenance of this procedure.
4.2 HSE management committees at all levels are responsible for reviewing and approving the
plans and resources for the development, revision, communication, training and implementation
of the Procedure for Pre-startup Safety Review Management, and for auditing and monitoring the
overall implementation of the procedure to ensure the quality of the implementation.
4.3 Corporate functional departments of CNPCI are responsible for facilitating the promotion
and implementation of this procedure.
4.4 All companies shall formulate, manage and maintain their respective pre-startup safety
review management procedures according to this procedure. Relevant functional departments of
all companies are responsible for the implementation of the procedures and shall provide
corresponding training, supervision, measurement and assessment.
4.5 HSE departments of all companies are responsible for providing consultancy, support and
audit for the implementation of their pre-startup safety review management procedures.
4.6 All grass-root units (plants, stations, crews, workshops, installations and facilities) shall
implement the pre-startup safety review management procedures of their companies and provide
suggestions for improvement of the procedure implementation.
4.7 All relevant staffs shall receive training for pre-startup safety review, implement pre-
startup safety review management procedures, participate in audits for pre-startup safety review,
and provide improvement suggestions.
5. Management Requirements
5.1 Basic Requirements
5.1.1 Pre-startup safety review spans through project transfer and system operation. It is
designed to identify all the aspects which may have impact on the safe operation of processes and
equipment to ensure the following conditions are satisfied:
——construction and installation of equipment is in accordance with design specifications and
established standards;
——procedures to guarantee the safety operation of equipment, such as safety, operation,
maintenance, and emergency procedures, are in place;
——appropriate process hazard analyses have been completed and all the recommendations
have been either implemented or addressed in a reasonable manner;
——management of change has been followed and process safety information havebeen
updated;
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
——each employee involved in operation or maintaining the process or equipment has been
adequately trained and acquired the required certifications;
——All the requirements about process safety management have been met and all the
deficiencies requiring prior correction have been resolved and such resolutions have been verified.
5.1.2 Pre-startup safety review is a prerequisite for project commencement. Projects requiring
PSSR include but are not limited to:
——New, or modified or expanded systems (including leased systems);
——Modified processes or equipment which involve flammable, explosive, toxic or hazardous
materials and high temperatures and high pressures;
——Facility shutdown and overhaul projects;
——Spudding or penetrating into oil and gas bearing formations or abnormally high pressure
formations;
——Adoption of new processes or new technologies;
——Other projects such as restarting the operation of oil or gas plants or stations.
5.1.3 PSSR teams should be built according to the authorization level of the specific projects
and conduct PSSR according to the checklists prepared in advance.
5.1.4 Considering the scale and work schedule of a project, PSSR may be conducted multiple
times in different stages and by focusing on different areas.
5.2 Establishment of PSSR Teams
5.2.1 Team Composition
5.2.1.1 To guarantee the quality of a PSSR, a PSSR team should be established in advance
according to the project schedule. A team leader should be designated depending on the
authorization level of the project concerned (usually the project manager, production manager or
chief engineer will act as the team leader). The team leader then proceeds with team member
selection and work assignment.
5.2.1.2 A PSSR team may be consisted of employees specializing in process technology,
equipment, inspection and maintenance, electric instruments, main operation and human resource
as well as HSE professionals. The team should also include representatives from the contractors,
parties involved in construction, design and supervision, and external experts with special
expertise and experiences.
5.2.2 Work Assignment
Area or Unit Chief
—— establishing the PSSR team and providing professionals and other resources required by
the PSSR of project;
——leading the development of PSSR checklists together with the PSSR team leader;
——chairing the PSSR planning meeting and review meetings;
——reviewing the resolutions for all deficiencies requiring prior correction and approving the
startup of projects for which he/she has authority over upon confirmation together with the PSSR
team of the completion of the correction of all deficiencies requiring prior correction;
——supervising, inspecting and following up the completion of the correction of remaining
deficiencies;
——providing adequate resources for the implementation of all the safety and environmental
measures before startup;
——ensuring all employees have received training in the PSSR management procedure.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
4
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
filed;
——Process hazard analysis recommendations have been implemented;
——Operation procedures, operation cards and relevant safety requirements comply with the
requirements for processes and technologies and have been approved;
——Changes to processes and technologies, including changes to processes and instrument
drawings, have been approved and recorded;
——Public utilities are ready for the startup of the project;
——The production and operation command system functions well.
5.3.2 Personnel
——All staffs involved have received trainings about the startup plan, HSE hazards, operation
procedures, maintenance procedures, safety specifications and emergency response;
——Contractor staffs have received HSE training corresponding to their work, including
hazards of potential fire, explosion or release of toxic substances in the workplace or the
surrounding area as well as emergency response;
——Newly hired or transferred staffs are clear about the possible risks associated with their
work and are competent in their work.
5.3.3 Equipment
——Equipment has been made, transported, stored and installed according to design
specifications;
——Equipment inventory and records of equipment operation, inspection, repair and
maintenance have been established as required and items, procedures and frequencies for
equipment testing and inspection comply with the relevant requirements;
——Risks caused by changes to equipment have been analysed, procedures to guarantee the
safety of equipment startup and operation, such as equipment startup plans, operation procedures,
maintenance procedures, safety specifications and emergency response plans, have been updated
and distributed to relevant people and the provisions in HSE – 6.8 Procedure for Process and
Mechanical Change Management has been followed.
——All the other auxiliary systems are ready.
5.3.4 Incident Investigation and Emergency Response
——Corrective measures based on lessons leant from previous incidents have been
implemented;
——Emergency response plans are in consistency with process safety information and staffs
involved have received training about emergency response plans.
5.3.5 Environmental Protection
——Emission and discharge reduction equipment can operate normally;
——Waste (including commissioning wastes and defective products) treatment practices have
been determined;
——Environmental incident response procedures and resources (people, equipment, materials,
etc.) are in place;
——Environmental laws, regulations and standards applicable in the host country and the
environmental policies and procedures of the Company are complied with.
5.4 Process
5.4.1 Planning Meeting
The Area or Unit Chief and the PSSR team leader shall call all team members for the PSSR
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
6
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
results of the corrections. Production and operation departments shall supervise the process of
PSSRs.
5.4.4.2 All deficiencies requiring prior correction must have correction plans including
corrective measures, responsible person(s) or units, schedules for correction and deadlines for
correction completion. The Area or Unit Chief should hold regular (generally once a week)
review meetings together with the PSSR team to follow up the progress of the correction of
deficiencies requiring prior correction until they are all corrected.
5.4.4.3 Upon completion of the correction of all deficiencies requiring prior correction, the
Area or Unit Chief should review the correction results with the PSSR team. Upon acceptance of
the correction results, the PSSR team leader should confirm in the PSSR checklists and report
and pass them to the Area or Unit Chief.
5.4.4.4 The Area or Unit Chief may approve the PSSR report only after having confirmed that
all deficiencies requiring prior correction have been corrected and all remaining deficiencies have
got monitoring measures and correction plans with designated responsible person(s) (or units)
and deadlines for completion. For a project sponsored by the area or unit itself, the project may
be started upon the approval of the PSSR report. For a project sponsored by the upper level of
management, the approval of the PSSR report by the Area or Unit Chief is a pre-requisite and a
primary condition for the startup and acceptance of the project.
5.4.4.5 After project startup, the PSSR team leader and the Area or Unit Chief should continue
to track the progress in the correction of remaining deficiencies and make acceptance upon the
completion of their corrections. After acceptance, the PSSR team leader should record the date of
completion on the PSSR checklists and report.
5.5 Document Filing
All the documents concerning the PSSRs performed, including PSSR checklists, PSSR reports,
correction plans for remaining deficiencies and follow-up plans, shall be filed.
The drawings, design documents and other data for deficiencies involving changes should be
updated and filed.
Upon completion of the correction of remaining deficiencies, the responsible person should
send a written notice to the Area or Unit Chief. The written notice should be filed together with
the PSSR checklists, PSSR reports and process hazard analysis reports of the project to ease
future document searches.
5.6 Assessment
After completion of a PSSR, the process safety management coordinator should assess the
PSSR performed for integrity and contents.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
6.3 Deviation
All companies shall report to Corporate HSE Department of CNPCI for any deviation from
this procedure in their own pre-startup safety review procedures. Any deviation in the
implementation of the procedure shall be authorized by direct supervisors. Deficiencies shall be
documented and the documentation must include the relevant facts justifying the deviation
decision. Deviation authorization must be renewed annually.
6.4 Training and Communication
This procedure should be communicated throughout CNPCI. All relevant staff, including
contractor workforce, should be provided training as appropriate. Training records must be
maintained.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
9
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table A (Continued)
The whole category is not applicable
Check process pipelines and equipment Select Deficiencies requiring actions
Review results or
overhauled or maintained Remaining
Deficiencies
requirements for
Irrelevant Relevant requiring prior
deficiencies correction
correction
1.3 Check the shutdown process record of
critical equipment, confirm that the person
responsible for the equipment has signed
and filed the record and confirm if the
shutdown process complies with the
shutdown procedure.
14. Install all plugs (screw plugs or blind
plates) properly
15. Confirm that all valves are set at correct
positions.
16. Check the air-tightness of all connection
parts related to the maintenance.
17. Check the blind plate checklist and
attach a signed copy of the checklist to this
report
The whole category is not applicable
Select Deficiencies requiring actions
Flanges Review results or
Deficiencies requirements for
Remaining
Irrelevant Relevant requiring prior correction
deficiencies
correction
10
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table A (Continued)
The whole category is not applicable
11
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table A (Continued)
The whole category is not applicable
Other relevant systems
Select Deficiencies requiring actions
(power, cooling and Review results or requirements for
Remainin Deficiencies
circulating systems) Irrelevant Relevant g requiring prior correction
deficiencies correction
39. Check if relevant systems
meet start-up requirements.
40. Check if power systems
have passed pre-startup
insulation tests and seal heads
meet explosion proof
requirement.
The whole category is not applicable
12
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Reviewed by
Brief description of the project under review:
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
17. Have any other materials requiring
clearance been cleared?
18. Are there enough signboards or
fences to clearly mark working areas
or dangerous zones?
19. Are exits clearly marked?
20. Has personal exposure to
chemical materials during clearing
and maintenance been minimized?
21. Are storage areas clearly marked?
Are there any clearly written
procedures governing the
loading/offloading and use of
compressed gas cylinders?
22. Is there any measure to prevent
people from contact with high/low
temperature and high/low voltage
power supply?
23. Are materials placed in order and
easily accessible?
24. Are vessels, storage tanks and
operation equipment clearly marked?
25. Has equipment out of service
been isolated or marked?
26. Can safety showers and eye wash
equipment work well?
27. Are positive pressure respirators
adequate in number, meeting relevant
standards and in good and reliable
working conditions?
28. Is the connection for nitrogen
system different from that for
instrument air?
29. Are confined spaces at site clearly
marked?
30. Are audio and visual alarms
certified to be qualified, within the
valid period and can function well?
31. Is there a checklist and reaction
matrix or safety instruction for
chemicals within the area?
32. Is entry into production areas
controlled?
33. Are “Do Not Touch” signs clear
and conspicuous?
34. Are all the MSDSs the latest? Can
they be found at site?
35. Are material hazard training
materials and communication
procedures the latest?
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
Deficiencies requiring
Select Review
Process and equipment safety actions
Deficiencies results or
Remaining
Irrelevant Relevant requiring prior requirements
deficiencies for correction
correction
36. Have process and equipment start-up plans been prepared and
approved?
37. Are temporary safety measures in the start-up plan in place?
38. Has equipment been equipped with protective devices as required?
39. Are there latest MSDSs for lubricating oil and sealing liquids?
40. Check if auxiliary materials meet process and equipment
standards.
41. Check if auxiliary materials meet process and equipment
requirements and are adequate in quantity
42. Are the loading capacities for floors, guide rails, triangle derricks
and lifting slings clearly marked?
43. Can equipment be cleaned, isolated and maintained?
44. Are operation steps for key valves specified in the process flow?
45. Can valves be locked according to the lockout/tagout procedure?
46. Are valves easy to access for operation purpose?
47. Are required isolations placed at intersections of pipelines
containing different materials?
48. Are pipelines checked one by one as required?
49. Have pipe sections out of service been isolated or removed?
50. Are sewage discharge and venting points at locations easy to see
and operate?
51. Are sampling points at locations easy to see and operate?
52. Are sampling points enough?
53. Are pipelines properly supported as required?
54. Are cantilever connections supported?
55. Are all pipeline supports in close contact with the pipelines and
bearing even weight?
56. Are pipeline expansion absorption devices and measures in place?
57. Does the use of hoses and flexible connections meet safety
requirements?
58. Have backflow prevention devices (check valves) been installed?
59. Are locations, directions and angles of check valves installed
correctly?
60. Are locations, directions and angles of filters installed correctly?
Are they easy to open and clean?
61. Are temporary connection pipe sections of appropriate length?
62. Have static jumpers and groundings been installed on pipelines as
required?
63. Have cathodic or anodic protections installed for underground
pipelines?
64. Are insulations used for mandatory cathodic protections to prevent
electric current from entering other pipelines and equipment?
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
65. Have items 62, 63 and 64 been tested? Have test records been
filed?
66. Have pressure test liquids, chemical cleaning liquids and neutral
liquids for commissioning in pipelines and equipment been cleaned?
67. Are gaskets fit for the materials and temperatures of the process?
68. Are gaskets fit for the pressure levels of valves and pipelines?
69. Do gaskets and flanges match the connections of equipment?
70. Are flange gaskets placed at correct positions?
71. Check if flanges have any damages.
72. Have air-tightness tests been conducted for flange connections?
73. Check if bolt gaskets are appropriate and complete.
74. Does installation of bolts and nuts meet relevant requirements? Do
they become loose?
75. Do release points for safety valves lead to safe positions? (Posing
no threat to either people or equipment)
76. Are release pipes for safety valves adequately supported and fixed?
Do pipe diameters meet relevant requirements?
77. Have isolation valves of safety valves been opened completely?
78. Have isolation valves of safety valves been locked or sealed?
79. If possible, verify if isolation valves are really opened.
80. Are locking/unlocking valves in process pipelines at correct status
and locked? (To avoid formation of enclosed pipe sections and mixing
of different materials)
81. Do safety valves of direct discharge type have weep holes and rain
hats?
82. Are isolation valves of release valves in unlock state?
83. Are status checklists for isolation valves of release valves the
latest?
84. Do new pressure settings for safety valves meet relevant
requirements and communicated to operation and maintenance staffs?
85. Have vibration abatement devices for pipeline equipment been
installed?
86. Have fix bolts for expansion joints been loosened?
87. Have protective covers and rails for moving/rotating parts been
installed?
88. Have radiation equipment been protected as required?
89. Have lockout/tagout points been locked and tagged?
90. Are serial numbers of equipment and instruments are clear and
easy to read?
91. Are blind plates and spectacle blinds correctly installed, numbered,
tagged and registered?
92. Are discharge points equipped with receiving trays (pools) and
installed with blind plates or screw plugs?
93. Have thermal insulations been completed as designed?
94. Are three-way valves correctly marked?
95. Are pressure and temperature meters and flow indicators installed
at positions easy for reading?
96. Are all measuring instruments and meters certified to be qualified,
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
17
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
18
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
Deficiencies requiring
Select
Ergonomics actions
Deficiencies Review results or requirements for correction
Remaining
Irrelevant Relevant requiring prior
deficiencies
correction
136. Are control buttons, switches
and valves convenient for
operation? (Avoid excessive
stretching or bowing)
137. Are display screens and control
panels easy to see, understand and
operate?
138. Has heavy manual handling
been minimized?
139. Have glare and reflection from
working surfaces and screens been
removed?
140. Are work spaces for operators
and maintenance staffs big enough
and comfortable? i.e. big enough for
them to stand up, turn around and
bend 90 degrees with one foot on
the ground and both hands holding
one ankle.
141. Are emergency alarms resistant
from interference by process
operation noise? Can staffs hear
emergency alarm at any location?
142. Have repetitive forced actions
(e.g. rhythmic movements following
machines) been minimized?
143. Have manual handling of toxic
and hazardous materials been
minimized?
144. Has the time for staffs to wear
PPE, such as chemical protective
clothing and positive pressure
respirators, been minimized?
19
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
20
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
21
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
Select Deficiencies requiring actions Review results or
Process hazard analysis Deficiencies requirements for
Remaining
Irrelevant Relevant requiring prior correction
deficiencies
correction
178. Have process hazard analyses been conducted
for new and modified systems?
179. If yes, have recommendations proposed in
process hazard analysis reports been implemented?
180. Has the process safety coordinator filed all
recommendations?
181. If lack of process hazard analyses, have
recommendations based on pre-startup hazard and
environment aspect identification been implemented?
182. Have recommendations from process risk
analyses required by changes been implemented?
183. Has all process safety information related to
changes been updated? Including operation manuals,
alarm parameters, additional safety equipment,
deviations, set values, upper and lower safety limits
in normal operation, etc.
184. Have people directly responsible for processes
and equipment got all the process safety information
they need?
185. Has the process risk analysis report been
completed?
186. Does the process risk analysis report reflect
changes in the construction process?
The whole category is not applicable
22
Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
Deficiencies requiring
Select
Mechanical integrity actions
Review results or requirements
Deficiencies for correction
Remaining
Irrelevant Relevant requiring prior
deficiencies
correction
194. Is there a repair and maintenance procedure for all
equipment?
195. Has the quality and quantity control procedure for
maintenance materials and spare parts been developed
and approved?
196. Have critical equipment maintenance tracking
records been established?
197. Have the inspections and testing of the following
equipment been completed? Have the records been
filed? Has regular testing during normal operation been
included in the maintenance plan?
(1) Pressure vessels
(2) Pressure release and venting devices
(3) Control equipment, control logic and alarms
(4) Emergency response equipment, including
emergency shutdown and isolation devices or systems
(5) Firefighting facilities
(6) Pipelines for transporting toxic and poisonous
materials (including valves, restrictor valves, expansion
joints, hoses, etc.)
(7) High speed turbines, centrifugal separators and
other high speed rotary devices
(8) Material intake connectors of key process pipelines
(9) Electric and static groundings and static jumpers
(10) Emergency alarm system
(11) Monitoring instruments and sensors (for pressure,
temperature, flow, etc.)
(12) Pumps
(13) Hoisting and lifting equipment
(14) Ventilation systems
198. Have statutory inspections and tests been certified
by relevant regulatory authorities (or third parties) (e.g.
for pressure vessels, hoisting and lifting equipment,
firefighting equipment, etc.)?
199. Have all commissioning and testing preparations
been completed?
(1) Hydraulic tests
(2) Air tightness tests
(3) Chemical cleaning, passivation, etc.
200. Can spare parts of process pipelines and
equipment meet the minimum storage requirement?
201. Has an equipment lubrication plan been developed
based on equipment lubrication requirements?
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
Deficiencies requiring
Select
Quality assurance actions Review results or
Deficiencies requirements for
Remaining correction
Irrelevant Relevant requiring prior
deficiencies
correction
202. Have equipment provided by suppliers been verified to
meet the parameters in design specifications?
203. Has installation of critical equipment been confirmed to
meet the parameters in design specifications?
204. Has installation of critical equipment been confirmed to
meet the requirements in the equipment technical
specifications from the supplier?
205. Does the equipment quality inspection report, including
equipment manufacturing, assembling and installation,
comply with the quality assurance management plan of the
project? Has the report been filed together with design
documents?
206. All members of the JSSR team have conducted site
inspections and reached a consensus or signed for
confirmation that:
(1) Installation of all equipment meets the requirements in
design documents.
(2) Installation of all process pipelines is consistent with the
drawings.
(3) Installation of all gaskets meets the requirements in
design documents.
(4) Support to and fixation of all pipelines meet design
requirements and are adequate.
207. The JSSR team has confirmed at site that the use of all
low temperature materials (including containers, pipelines,
gaskets, flange bolts, etc.) meet the requirements in design
documents.
The whole category is not applicable
Deficiencies requiring
Select
Operating procedures actions Review results or
Deficiencies requirements for
Remaining
Irrelevant Relevant requiring prior correction
deficiencies
correction
208. Have safe work specifications (safety management
standards for high risky operations) been formulated, updated
and approved?
209. Have all safety related requirements during operations
(high risky job performance) been included in operating
procedures?
210. Are there any new safe operation requirements to be
added to operation procedures after changes to equipment?
211. Is it necessary to test updated operation procedures with
water, chemical solutions or other safe neutral solvents?
212. If necessary, is there any operation procedure to provide
assurance?
213. If the test proves that the procedure or the equipment
fails to meet the requirements, will the operation procedure or
deficiencies of the equipment be corrected?
214. Have operation procedures for processes and equipment
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Table B (Continued)
The whole category is not applicable
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Inspection team
LOCATION
SN Item description Y/N Review results or requirements for
correction
1 All equipment are spotted properly as per the rig lay out
& required safe distances.
2 Location entrance & exit clearly identified with signs.
3 All hazard signs are posted on location.
4 Proper trough to be provided behind brine/mud tanks for
draining waste to waste pit.
5 Hazardous and non- hazardous waste bins are provided
6 Adequate size of waste pit with proper lining has been
provided.
7 Ensure Confined Space Permit is completed and
implemented prior to all cellar entries. Cellar area
should be monitored for explosive gases/LEL, H2S &
O2 levels with a Sniffer.
8 Clean cellar, weld 4 dump valves on 42 conductor &
check cellar jet pump is working okay.
9 Ensure previous location is cleaned & leveled.
AIR WINCHES
SN Item description Y/N Review results or requirements
for correction
1 Check condition of and function where relevant:
a) Mountings
b) Marking plates indicating up and down
c) Marking plates indicating the SWL
d) Wire line drum guards.
e) Winch operating controls
f) Winch safety controls
2 Ensure man riding tuggers are clearly designated.
3 Check when mounting bolts last inspected or replaced.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
BOP HANDLING
SN Item description Y/N Review results or requirements
for correction
1 Check all functions are clearly labeled.
2 Check when the overhead BOP cranes were last
inspected and that they are currently certified.
3 Ensure that cranes are free from obstruction over their
full range of movement in the cellar pit area
4 Check operation of all visual and audio warning devices
fitted to BOP cranes.
DERRICK MAST
SN Item description Y/N Review results or requirements
for correction
1 Check that the ladders and resting platforms are
properly fastened and in accordance with the
regulations.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
DRAW WORKS
SN Item description Y/N Review results or requirements for
correction
1 Function test all controls.
2 Run the travelling block up and down and check
operation of:
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
a) Crown-o-matic
b) Crown block saver
c) Elmagco braking system
d) Emergency back-up system
3 Check maintenance records with particular
reference to break band replacement, NDT of
critical components.
4 Draw works cooling system OK.
5 Check system for leaks.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
FISHING TOOLS
SN Item description Y/N Review results or requirements for
correction
Physically check inventory of all fishing tools to
1 confirm that it contains all tools listed in the
contract.
Ensure that tools and grapples are available to
2 catch all of the Contractor's drill string and
crossovers.
Ensure that all fishing tools have been redressed
3 and inspected since last usage.
MUD AGITATORS
SN Item description Y/N Review results or requirements
for correction
1 Start all agitators before filling up the tanks.
2 All mud agitators in working condition in all tanks.
3 Check for noise and vibration.
Check general condition and security of agitators,
4 mountings and paddles.
5 Check system in place for locking out motors.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
MUD PITS
SN Item description Y/N Review results or requirements
for correction
1 Check general condition of:
a) Pits.
b) Gratings and access ladders.
c) Isolating, equalizing and dump valves.
2 Ensure pits are clearly labeled.
Fill each pit with water and check for leaks between
3 adjacent pits and through isolating, dump and equalizing
valves.
4 Pump through and check operation of all mud guns.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
SHALE SHAKERS
SN Item description Y/N Review results or requirements
for correction
1 Check the general condition of each shaker.
2 Run each shaker and check for:
a) Abnormal noise and vibration.
b) Oil leakage.
3 Check inventory of spare parts, e.g. motors.
Check shaker screens on all shakers and ensure all
4 shakers in working condition.
Check inventory of shaker screens and ensure that it is
5 suitable for the proposed drilling programme.
Check condition of valves on the header system and the
6 discharge chutes.
STABBING BOARD
SN Item description Y/N Review results or requirements
for correction
1 Check for safe installation of the casing stabbing board.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
SWIVEL
SN Item description Y/N Review results or requirements
for correction
1 Check for oil leakage
2 Check when new wash pipe was last installed.
3 Check for abnormal noise or vibration.
4 The above will be tested to rated working pressure at the
same time as the top drive.
TOP DRIVE
SN Item description Y/N Review results or requirements
for correction
1 Run the top drive up and down and check:
a) Guide rails
b) Fouling of cables and hoses with derrick and fittings
2 During test, check:
a) Functions properly labeled on control panel
b) All indicators / gauges working
c) All electric devices explosion proof
d) Oil leakage
e) Air leakage
f) Indicator lights operational
3 Install the IBOP and saver sub using the pipe handler.
4 Function test the remote operated IBOP (Kelly cock).
5 Pressure test the IBOP(S) and top drive mud circulation
components to rated working pressure.
6 Using Rotary tong with tong pull line check calibration
of the torque indicator for make-up and break-out
torque.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
ADDITIONAL CHECKS
SN Item description Y/N Review results or requirements
for correction
1 All ladders fixed & hand rails provided.
2 All crew available for all shifts as per contract.
3 Mud pits and charts calibration by geoloyg/datalog. Kill
sheet is prepared
4 Mud preparation as required volume and density.
5 Prepare HI-VIS mud 90+ for sweeps.
6 Rig up recycle pump from waste pit to mud tanks.
7 Check flow-line /all lines are clear of all cutting & mud-
cake.
8 Install water line to water tanks from water wells & fill
all tanks.
9 Rig up suitable lighting around tig, cat walk &
cementing silos.
10 All cutting troughs & overflow pipes to be put from
tanks to waste pits.
11 Check availability of proper X-over safety valves on rig
floor.
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
Inspection team
Review results
Items for review Item Description or requirements
for correction
A complete system of management documents are in place,
1.
including a work permit system which is strictly followed.
Blowout, H2S and explosion response plans are in place,
2. Management emergency drills have been conducted regularly and records are
documents made.
and records Well control devices meet the requirements in the original design,
3. and well control measures specific to critical wells, complicated
wells and special wells have been implemented.
4. Well control equipment are regularly inspected and maintained.
Staffs wear proper PPE as required, hold valid well control
5. certificates and strictly observe safety procedures, rules and
specifications.
Protective equipment, including H2S monitoring devices and
positive pressure type respirators, are regularly inspected and
6.
calibrated, adequate to meet demands and remain intact and
Basic operational.
requirements Production installations and electric equipment have proper
7.
grounding.
No naked fire is used at the site. Diesel engines are equipped with
8. flame traps. Electric equipment is explosion proof. Fire control
equipment are adequately equipped and in valid period.
The safety distance between the wellhead and duty room,
9.
warehouse, testing and logging room, geology room, boiler room,
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
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Doc. Title: Procedure for Pre-startup Safety Review Doc. No.: CNPCI Corp HSE – 6.5
Management
Doc. Type: Procedure Revision: 2.0
Custodian: Corporate HSE Department Issue Date: July 2012
The report can only be signed for approval after all the deficiencies requiring prior correction have
been corrected.
I have reviewed and verified together with the PSSR team Approved by (Area or Date:
that all the deficiencies requiring prior correction have been Unit Chief):
corrected and all the remaining deficiencies have got monitoring
measures and correction plans and the system can be started
safely.
Remaining deficiencies:
Deadline for Confirmation Actual
Remaining Responsible Recommendations for
Correction of Correction Completion
Deficiencies Person(s) Corrective Measures
Completion Completion Date
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