ICI PAKISTAN LTD. SODA ASH BUSINESS SA HSE P-19.13.01 Page 1 of 7 CONTROLLED EQUIPMENT Written/Updated By | Syed Abid Mehdi Project & Development Manager We 4 S| qo | Signature with Date Reviewed By | Adeel Hassan Maintenance Manager Power Services Signature with Date Farooq Sharif HSE & Training Manager be bed Ahir Signature with Date ‘Muhammad Saeed Anwar Manager Power Services cs (Operations) ae Tff2h Signature with Date | Tee za ‘ Engineering Manager as ee ature with Date Muhammad Umer Mustaq | Works Manager ol Signature ih Date ‘Approved By Muhammad Abid Ganatra | Vice President ae, ICI PAKISTAN LTD. SODA ASH BUSINESS SA HSE P-19.13.01 Page 2 of 8 CONTROLLED EQUIPMENT 1 PURPOSE To define responsibilities and essential requirements for sustained safe operations through the implementation of Controlled Equipment programs at ICI Pakistan Soda ‘Ash Works. SCOPE ‘This procedure is based upon principles established in ICI Pakistan HSE&S CG 19.13; it supports the ICI Pakistan HSE&S Standard that requires safe systems of work for the design, installation, operation, maintenance and integrity of equipment. This guideline identifies the HSE principles required to be incorporated into management systems and procedures to ensure integrity of controlled equipment. it applies to new, reused, modified and existing equipment at ICI Pakistan Limited, Soda Ash Works, Khewra. DEFINITIONS, 3.4 Controlled Equipment Equipment that should be given special attention because of legislative or company HSE&S reasons for purposes of ensuring integrity. 3.2. Competent Person(s) Person(s) having demonstrable ability in terms of qualities, skills, experience, and training to consistently carry out specific work activities to a defined standard, 3.3 Responsible Executive The Responsible Executive is the person identified by the Business, Region or Group Department as having the following responsibilities that are included in each Group Engineering Procedure: (@) Ensuring that local engineering procedures are provided in accordance with the Group Engineering Procedure, and that they are implemented (b) Approval, in consultation with the IC Group Engineering Manager (or nominee), of the appointment of Responsible Engineers and other key individuals required by the Group Engineering Procedure; (See Group Engineering Manager) (©) Ensuring that staff with the required competence are appointed in wri (d) Ensuring that systems for GEP compliance audits are established. In case of PE, this role is assigned to Business V.P. 3.4 Responsible Engineer The responsibilities of the Responsible Engineer are specified in Group Engineering we Ox- ICI PAKISTAN LTD. SODA ASH BUSINESS SAHSE P-19.13.01 Page 3 of 8 CONTROLLED EQUIPMENT Procedures. Itis essential that the individual has both the competence and the authority to fulfl the accountabilities. On appointment the Responsible Engineer shall carefully consider such factors and refer any concems to the Responsible Executive and, if necessary, the ICI Group Engineering Manager. ‘The Responsible Engineer is responsible for ensuring the appointment of the ‘appropriate key individuals for the production unit/facilty 3.5 Operations Manager Operating Manager is a person responsible for the management of a production unit or facility. The responsibilities of the Operating Manager are specified in Group Engineering Procedures. Itis essential that the individual has both the competence and the authority to fulfil the accountabilities. On appointment, the Operating Manager shall carefully consider such factors and refer any concerns to the Responsible Executive. ‘The Operating Manager is responsible for the appointment of the appropriate key individuals for the production unitfacilty 3.6 Registration Registration means identifying each Controlled Equipment, allocating and marking such systems with a unique identitication number and assembling key information in a system of equipment files. 3.7 Unacceptable Situation ‘An unacceptable situation is one resulting in one or more of: 2) Harm or serious nuisance to public b) Serious harm to public on site ©) Serious harm to the environment 4 REQUIREMENTS AND RESPONSIBILITIES, 44, REQUIREMENTS a. The following should be identified as controlled equipment: (1) Electrical Safety (see GEP 2) (as categorized in CG 19.15); 54 86Q ICI PAKISTAN LTD. ‘SODA ASH BUSINESS SAHSE P-19.13.01 Page 4 of 8 CONTROLLED EQUIPMENT (2) Lifting equipment (e.g. hoists, cranes) (see GEP 9); (3) Machine guarding (including robots and automatic guided vehicles and interlocks to prevent injury by machinery); (4) Fixed and portable gas detectors; (8) Temporary access equipment or structures (e.g. ladders, scaffold, mobile work platforms). b. The following additional equipment should also be assessed as a minimum: (1) Portable power tools; (2) Emergency equipment; (3) Equipment whose operation is key to SHE performance (e.g. local exhaust ventilation, vent gas analyzers, dust filters, PPE). . Registration of all equipment (as mentioned in “a” above as Controlled Equipment) d. Assessment of equipment (as mentioned in "b” above for registration / listing / identification as Controlled Equipment) e. Formal review process for all isted Controlled Equipment. f. Implementation of a registration, periodic inspection regime for all listed controlled equipment. 9. A documentation file to be maintained for all listed controlled equipment. fh. Trained competent resource to implement above requirements. i, All Controlled Equipment to be operated within design limits, i. No Controlled Equipment to be operated beyond inspection due date without appropriate approval by competent authority, 4.2, RESPONSIBILITIES 4.2.1. Vice President as Responsible Executive shall have an overall responsibility to ensure that requirements of this procedure are implémented in Soda Ash Business. He shall make available necessaty resources and make , 4 86. ICI PAKISTAN LTD. SODA ASH BUSINESS SA HSE P-19.13.01 Page 5 of 8 CONTROLLED EQUIPMENT the appointments of Responsible Engineer, Operating Manager and Project ‘Manager in writing 4.2.2. The Responsible Engineer shall ensure that: a. A formal review procedure is applied to those items assessed as controlled equipment to ensure that: (1) The appropriate design standards and construction materials are used, and (2) To establish the safe design, working limits and protective systems for the control of hazards, No modifications or re-rating of controlled equipment should be carried cut without the approval of the competent person and should include the appropriate documentation. b. Planned and preventative maintenance schedules are defined, ©. Periodic inspection frequencies and inspection requirements are defined d. All controlled equipment is inspected as per defined frequency, calibrated against defined criteria. The inspection and any work done should be recorded The inspection status should be made visible to users (e.g. use of colour coding or labels). e. Adocumentation file for each item or groups of items, of controlled equipment is established and maintained {Personnel employed in the use, maintenance, repair, examination of controlled equipment is competent by virtue of having the appropriate knowledge, training and experience. g. Equipment is kept secure when not in use, h. Any required local procedures are in place to implement the requirements of this procedure. 4.2.3, The Operating Managers (respective plant managers) shall ensure that: a. Controlled equipment are operated and maintained so as to stay within its design limits. fh vebe ICI PAKISTAN LTD. SODA ASH BUSINESS SAHSE P-19.13.01 Page 6 of 8 CONTROLLED EQUIPMENT b. NO controlled equipment is operated beyond its specified "Next Inspection Due Date" without prior approval from Responsible Executive. c. Persons using controlled equipment are competent by virtue of having the appropriate experience, training and experience. 4.2.4. For new projects, the Project Manager shall ensure that identification / assessment of equipment for registration as Controlled Equipment is carried out as specified in this procedure. 4.2.8. The Commissioning Manager is responsible for ensuring that the controlled ‘equipment is checked and its installation complies with the design intent prior to ‘commissioning, DOCUMENTATION List of Controlled Equipment Appendix | List of Responsible Persons Appendix I COMMUNICATION & TRAINING The requirements of this procedure shall be communicated to all concerned. Training shall be carried out for all concemed managers and staff and documented. REFERENCE ICI Pakistan HSE&S CG 19.13 Controlled Equipment AMMENDMENTS This is 2° issue as per ICI Pakistan HSE&S CG-19.13. we 156° ICI PAKISTAN LTD. SODA ASH BUSINESS SA HSE P-19.13.01 Page 7 of 8 CONTROLLED EQUIPMENT APPENDIX | LIST OF CONTROLLED EQUIPMENT ‘Sr Title Unique Identification # ‘Area / Location ge are+, ICI PAKISTAN LTD. SODA ASH BUSINESS. SA HSE P-19.13.01 Page 8 of 8 CONTROLLED EQUIPMENT APPENDIX II LIST OF RESPONSIBLE PERSONS Responsible Engineer [een 1 Electrical Safety QaB 2 instrumented Protective System AB 3__[GEP-14.4 | Pressure System AH 4 [ce-14.5 | critical Machine System AH S| GeP-14.6 | Hazard studies MYA | 6 | GeP-14.7 | Plant Structures & Pipe Bridges AR 7 | GkP-14.8 | Ground & Ground Water Protection MYA 8 _[GEP-14.9 [Lifting Equipment AR 9 | GEP-14.10 | HSERS Aspects of Project Equipment UA 10 _| Gep-14.11 | Transport Containers and Loading & off Loading Terminates | HK a1 | GeP-14.12 [Fire Safety Fs 12 | GeP-14.13 | Work Equipment Guarding & Interlock HK Operating Managers Plant °A’ RMAJ Plant “B/C” AS. Power Services MSA Project Managers To be nominated as and when required ys £6