Engineers India Limited: Safety During Start-Up & Commissioning

Engineers India Limited
SAFETY DURING START-UP & COMMISSIONING
08th Jan, 2018

Contents
Introduction
Key Terms
Why Operational Safety
Pre-Commissioning Activities
Hazards during Pre-Commissioning
General & Specific site safety procedure
Hazardous Properties of Chemicals
Safety during Commissioning
11 September 2019 2
Key Terms
• The freedom from set of conditions with the potential
for leading to injury to persons, damage to property
SAFETY
or work interruption which affect the attainment of
project objectives.
• An assembly of all systems/ a group of units

PLANT
including auxiliaries/other facilities.
• Breaking down of the plant into precisely

SYSTEM demarcated traceable sections or components to
facilitate smooth start-up of the plant.
11 September 2019 3
Key Terms
• An assembly of systems which together form a
distinct operating section, and is a part of the
plant. Unit is a part of the plant which can be
UNIT operated independently due to availability of
surge between units and / or which produces a
distinct end / intermediate product.
• The plant / unit / system is considered
mechanically complete when all the construction
work is completed in accordance with the
MECHANICAL drawings, specifications, guidelines, codes and
COMPLETION regulations; all equipments and machines
erected and aligned; all instruments installed and
pipelines hooked-up; all testing and inspection
activities completed.
• A listing of deviations from piping and
instrumentation diagram and the requirement of
CHECKLIST safety, start-up, operation and maintenance. For
Licensed units responsibility of check listing is
limited to as per P & ID.
11 September 2019 4
Key Terms
• A characteristics of the system/plant process that

HAZARD represents a potential for an accident causing
damage to people, property or the environment.
• A specific unplanned event or sequence of events

ACCIDENT
that has undesirable consequences.
• Risk is the probability that human, Property or the

RISK environment may suffer harmful consequences as a
result of exposure to a hazard.
11 September 2019 5
WHY DO WE REQUIRE OPERATION SAFETY??
DAMAGE
SAFE
TO
SAFETY LIFE,
LIFE,
CHEMICAL
AS PROPERTY
PROPERTY
AND PHYSICAL
A AND
AND
HAZARDS
BARRIER ECO-SYSTEM
ECO-SYSTEM
‘INTRINSIC SAFETY’ REMOVES THE HAZARD ITSELF.
11 September 2019 6
SUBTRACT OPERATION SAFETY
11 September 2019 7
SAN JUANICO DISASTER PEMEX, MEXICO, 1984
BEFORE AFTER
11 September 2019 8
LPG FIRE AT VALERO, MCKEE REFINERY, 2007
11 September 2019 9
JAIPUR FIRE ACCIDENT , 2009
• 11 Dead
• Loss of ~ Rs.280 Crores
11 September 2019 10
EXPLOSION IN VENEZUELA'S LARGEST OIL REFINERY ON
25-08-2012
• 48 Dead (official figure)

• initial Report indicate poor
maintenance as chief cause
When Safety fails (such as: Seveso, Bhopal, Piper Alpha, Toulouse,
Buncefield, Texas City, etc.) Consequences of one incident alone bear the
potential to cause significant problems/losses:
 Multiple casualties
 Environmental Damage
 Business & reputation (brand, revenue or entire industry sector)
 Legal
 Management becomes distracted from other aspects of the business
 Management becomes distracted from other aspects of the business
CAUSES OF ACCIDENTS IN OIL INDUSTRY
1%
Sabotage & Arson
5%
Design
5%
Natural Hazards
11 %
Process Upsets
12 %
Unknown
22 %
Operator Error 44 %
Mechanical
0 10 20 30 40 50
Source : Harry J. Toups LSU Department of Chemical Engineering ,SACHE 2003 Workshop
FORMAT SYSTEM
The following formats (Format-I, II, III, IV and V) to be used during pre-
commissioning and Commissioning activities.
Format A – Internal Intimation regarding system completion
Format B - Internal Check lists
Format-I – Intimation regarding system completion
Format-II– Check lists
Format-III– Ready for pre-commissioning certificate
Format-IV– Ready for Commissioning certificate
Format-V– Successful completion of commissioning certificate
ACTIVITIES DURING PRE-COMMISSIONING
Pre commissioning activities are activities performed in order to make the
plant / unit / system ready for commissioning after the plant/unit/system are
mechanically completed. These activities include, but not limited to the
following,
 Inspection of tanks/vessels/columns etc for cleanliness & any other

construction debris.
 Isolation / removal of inline components / instruments for flushing
operation & re-install them on the completion of these operations.
 Flushing & cleaning of pipes / vessels / equipments by air blowing /
water flushing / steam blowing / oil flushing / degreasing.
• Cleaning & flushing of sewer systems & blow down systems.
• Chemical cleaning for pipes / vessels etc as required as per the

procedure given by specialist agency.
• Passivation of lines / vessels / equipments as required.
• Testing of safety valves & other safety devices
• Testing of heat exchangers for leaks
• Checking out interlock systems & emergency shutdown systems
• Installation of temporary blinds / spools to enable isolation of systems

during pre-commissioning stage.
• Refractory drying for furnaces
• Removal of temporary blinds just prior to commissioning
• Loading of catalyst, molecular sieve, packing etc.
• Water run / dry run for process system to check the functioning of
controlling systems
• Leak test of vessels / piping /equipments
• Drying of columns / reactors /equipment with dry air / nitrogen as

required
• De-airing of the systems by nitrogen purging / steaming as required
HAZARDS DURING PRE-COMMISSIONING
CHEMICAL CLEANING OF LINES AND EQUIPMENT

• The chemicals may leak due to equipment failure or could be spilled due
to failure of fittings and causes burns to the skin on contact or injure the
eyes, or contaminate the environment.
• If the chemically dosed water is drunk, it may result in illness or death.

Equipment or fittings may fail and cause injuries.
AIR BLOWING OF LINES

• Flying particles at open ends may result in eye injuries. High noise
levels are often.
STEAM BLOWING OF LINES (LP,HP,VHP)
• Steam will heat up the lines and equipment, which can cause metal burns.
• Steam blowing is also associated with high levels of noise which may
harm the ears.
• Condensate if fall on the person or direct hitting with steam can cause
severe burn injury.
• If steam blowing is going on in closed area like blower shed, compressor
shed etc. ,it can cause poor visibility & in turn can cause slip & fall
incidents.
• Normally superheated steam beam cannot be seen (only noise & heat can
be sensed),it can also cause burn injury.
STEAMING OUT OF LINES, VESSELS, COLUMNS
• If the line, column is under pressure with a product or substance it will

escape and cause burns, eye injuries, or other types of serious injuries,
fires, gas leaks/clouds etc.
REPLACING STUDS/BOLTS/ GASKETS/ INSERT OR REMOVE SPADES
• Failure of equipment or fittings / tubes which could lead to eye & hand
injuries and environmental contamination.
ROTATING EQUIPMENT AND OTHER ELECTRICAL TESTING
• There is always a danger of electrical shock and/or unguarded moving

parts that may cause injuries.
• Apart from this there is also the possibility that the equipment may fail.
HYDRAULIC TESTING OF INSTRUMENT SYSTEM
• Failure of instrument system may lead to injuries to persons working

around.
REFRACTORY DRY OUT
• Spillage of Furnace oil, Gas Leak, Fire, Explosion.

• Hot Surface which can cause burns, eye injuries, or other types of serious
injuries.
CATALYST LOADING
• Confinement, Fall of Object, Fall from Height, Chemical Dust
HAZARDOUS MATERIALS
Hazardous materials are substances capable of posing a risk to personal
health and safety. Hazardous materials/substances could generally be
classified as follows:-
Toxic Materials (H2S,Ammonia,Benzene,Toluene)

A toxic material is one which adversely affects the body and organs.
Carcinogenic Materials (Benzene, Toluene)

Materials, which have the potential to cause cancer, are known as carcinogens.
Sensitizers (Formaldehyde)
Sensitizers are chemicals which after repeated exposures can cause an allergic-
type reaction.
Corrosive (Caustic Soda, Acids)

Corrosive are chemicals that cause visible destruction or changes in living tissues
by chemical action upon contact.
HAZARDOUS MATERIALS
Irritants (Chlorine, Alkalis, Some solvents)
An irritant is a non-corrosive chemical that causes a reversible inflammatory effect on
living tissue by chemical action on contact.
Asphyxiants (CO,N2,CO2)
Chemicals/gases which can cause suffocation by restricting the uptake of oxygen or
by respiratory paralysis or by diluting/displace oxygen below levels needed by the
body
Flammable & combustible liquids (HC,H2)

Liquids that give off enough vapors to form an ignitable mixture with air and produce
a flame when a source of ignition is present.
The best way to protect your health and safety is to know about each of the
chemicals being handled, or worked with, MSDS can be used for the same & must be
displayed wherever practicable
GENERAL SITE SAFETY PROCEDURE
RESTRICTED AREAS INSIDE SITE
• Identification of Restricted areas
• Barricade with tapes or polypropylene 5mm dia ropes . These ropes shall have
placards indicating NO ENTRY.
• Control / guard entry of persons, equipment and vehicles
• Substation just before energizing will be put under guard with entry register
• Switch yard will be chain link fenced with gate kept under lock and key.
SITE SECURITY
• Controlling vehicles, men and material into site restricted areas inside the plant
premises
• Specific ID cards or Markings for the purpose of entry into restricted area to men
and vehicles / equipments, if required by Commissioning In-charge
• Prevent the presence of any unauthorized ignition source
SAFE TRAFFIC MANAGEMENT

• Blockage of Roads with temporary stands with placards for making the area no
entry for vehicles.
• Diesel engine driven vehicles needed for commissioning purpose will be fitted
with approved seal welded spark arrestors
FIRST AID / MEDICAL FACILITIES
First Aid boxes are to be maintained as per EIL HSE specifications. Close liasioning
with client First Aid center / local Hospitals for major injury/illness cases to be
maintained. Alertness and quickness shall be maintained all time.
EMERGENCY COMMUNICATION
List is to be maintained containing Contact numbers of
• Client & EIL site in charges & Commissioning coordinators

• Client ,EIL & Sub contractors Fire & Safety Coordinators
• First Aid center/Ambulance
• Local Hospitals
• Local Police stations
• Labour Commissioner
• Factory Inspector
BANNERS AND SIGNS
Banners and signs will be displayed on site to warn or inform people of hazards and
hazard zones, or to prescribe the use of certain personal protective equipment or to
prohibit certain activities. The following are possible but not Limited:-
• Prohibited smoking zones.

• In noise zones to wear ear protection
• Touching hot pipes, valves, equipment.
• Chemical cleaning of pipes, valves and equipment.
• Chemical, Oil spillage
• A possible particle missile during air blowing activates.
• Electrical hazards.
• Hazardous work overhead.
• Permit areas
• Do’s & Don’ts of Critical activities like heater firing.
SPECIFIC SAFETY PROCEDURE
CIVIL WORK:
• All the underground systems like OWS, CBD, SS (Storm Sewer System) shall
be ready & blocked at OSBL to avoid Hydrocarbon backing from commissioned
plant.
• SS system can be hooked up with the outside system prior to start the pre-
commissioning activities like flushing or dewatering pump can also be used for
emptying out the SS pit.
• A plan shall be made for safe hooking up of Underground system with OSBL
after completing the all hot work.
• Fire proofing shall be completed to vessels, piping and structures as per the
drawing
CLEANING OF PIPING (UTILITY & PROCESS )
Water Flushing: The flushing is carried out prior to leak testing. All the lines which
are to be air blown followed by water flushing shall be checked by site engineer at
the beginning and during operation.
• Valid Work Permit is available at site and followed meticulously

• Area is barricaded before starting the operation.
• Proper access/ platform provided wherever required.
• Equipment/ Line is identified.
• Trained and experienced gang is deployed on the job.
• Drain and disposal arrangement of the water has been identified (as per the
client’s instructions.)
• All temporary electrical installation is far away from drain point.
• PPE’s like hand gloves, goggles, face shield, helmet, Ear plug are provided to
operation team and are being used.
• Displayed board such as “Water Flushing is in Progress”
Air Blowing/Card Board Blasting): In cases where water is not desirable in the
piping system (e.g. instrument /plant air), flushing by pressurized air shall be
carried out.

• Area is barricaded before starting the operation.
• Equipment/ Line is identified.
• Trained and experienced gang is deployed on the job.
• Pressure gauge is installed which have been calibrated & valid calibration
certificate is available.
• Air pressure never exceeds the operating pressure
• Communication System like Walkie – Talkie is available (if required)
• Displayed board such as “Card Board Blasting is in progress” on the
equipment.
Steam Blowing/Target Blowing( Steam Lines, Turbines)

• Specialized & trained Team is deployed for steam blowing operation
• All the pipelines are insulated, If Insulation is not provided, Safety Caution Board
is provided.
• All temporary fittings are rated for the steam pressure.
• Proper silencers are provided for noise reduction at steam blowing end point
• PPE’s like Hand gloves, apron, face shield , goggles, helmet,, ear plug/ ear muff
are provided to operation team and are being used.
• All Vent areas are cordoned off
• All the spring pipe supports are unlocked.
• Area is barricaded before starting steam blowing of pipelines
• Contingency Plan is prepared and informed to all employees.
Chemical Cleaning, Degreasing, Alkali Boil out Operation (Compressor,
Steam Generators, WHB)
• Specialized & trained Team is deployed for steam blowing operation
• Portion of Pipelines to be chemically cleaned is positively isolated from the rest.
• Incoming/ Outgoing or Inlet / Outlet valves to pipes / equipment are closed and
tagged “DO NOT OPERATE”
• After neutralizing, drain and arrangements for disposing off the cleaning agent
has been identified (as per the client’s instructions.)
• Safety shower eyebath fountain is available / provided/ commissioned.
Alternatively, arrangement s for showering with water, flushing eyes with water
is available at site.
• MSDS is available at job location
• PPE’s like Hand gloves, apron, goggles, helmet are provided to operation team
and are being used.
• Contingency Plan is prepared and informed to all employees.
STATIC EQUIPMENT ( I.E.TANK, VESSEL,COLUMN REACTOR, ETC)
Cleaning:
• Gas test shall be done for Oxygen (%), Toxic gases (ppm), Flammable gases
(LEL) prior to entry and same to be monitored on regular intervals.
• Ensure positive blinding/isolation on all pipe line connections
• Communicate work hazards and precautionary measures to concern employees
through daily Tool Box talks, HSE Induction training.
• Deploy trained confined space attendant outside the vessel who shall maintain
the entry & exit register.
• Use of only flameproof portable lamps (24Volts) protected with glass & wire
mess inside confined space
• Provide adequate exhaust / ventilation
• Provide fire extinguisher near vessel. Also wherever required, keep ready fire
water hose as standby arrangement.
• Use of good quality of electrical cables. No joints shall be allowed.
STATIC EQUIPMENT ( I.E.TANK, VESSEL,COLUMN REACTOR, ETC)
Catalyst Loading:

• Procedure for Catalyst Loading is prepared
• Specialized & trained Team is deployed for catalyst loading operation
• After completing the cleaning operation and vessel is ready for catalyst loading
operation.
• Communication System like Walki – Talki , Life Line are available in place
• Equipment is under normal (21% Oxygen) atmosphere.
• Valid Test Certificate for the Crane is available at site & displayed on the crane.
• Rescue /retrieval procedure is prepared and practical training given to all staff.
• PPE’s like hand gloves, apron, goggles, helmet, dust masks are provided to
operation team and are being used.
ROTARY EQUIPMENT (I.E. PUMP, MOTOR, COMPRESSORS & TURBINES.)
Motor:
All the motors shall be tested under no load condition for its smooth functioning. Prior
to that following checks shall be carried out
• Double Earthing
• Secured with foundation.
• Flame proof motor/ Non-flame proof
• Authorized and trained person is on the job.
• Marking on the switches for “ON” & “OFF”, Emergency Shutdown.
• Communication system is in place
• Barricading of area with sign board.
• Covered with guard
ROTARY EQUIPMENT (I.E. PUMP, MOTOR, COMPRESSORS & TURBINES.)
Pump:
Following checks shall be performed prior to commission the pump
• Double Earthing
• Coupling Guard is in place
• Marking for direction of rotation
• Free movement of the shaft
• Oil cup provided
• Calibrated pressure gauge at discharge end
• NRV at the suction
• On-off valve / control valve at both the end (Suction & Discharge)
• Provision of Earthing jumpers at pump & pipeline joints
• No leakage from mechanical seal.
HAZARDOUS PROPERTIES OF CHEMICALS
HYDROGEN SULPHIDE(H2S)
H2S present in DHT,DCU,VGO HDT,FGTU,SRU.
• It is a toxic, flammable, and colourless gas. It has an offensive odour similar to that
of rotten eggs.
• Its auto ignition temperature is 260 deg. C and has a wide explosion range (i.e.,
LEL = 4.4 % & UEL = 46 %).
• At the concentrations above 100 ppm, sense of smell is lost.
• Vapour density is 1.2 times more than that of air.
• Hydrogen sulphide reacts violently with metal oxides in the presence of oxygen.
Exposure limits (as per OSHA)

• TLV = 10 ppm (15 mg/m3)
• STEL = 15 ppm (27 mg/m3)
• IDLH = 100 ppm
• Effects of H2S at various concentrations
Concentration Period Effect

ppm
0.13 - Threshold detectable odour
10 8 hours / day Threshold limit value
20 – 50 Less than 8 Dizziness, light irritation to the eyes
hours
50 – 100 1hour Strong irritation to eyes and respiratory
tract.
100 - 150 3 – 15 minutes Sense of smell is lost
100 - 150 30 minutes Dangerous, dizziness, paralysis of leg
muscle
500 – 1000 30 minutes Immediate unconsciousness
Above 1000 - Instantly fatal
Symptoms of exposure
a) Very acute
 Sudden loss of consciousness

 Abrupt stoppage of breathing
b) Acute poisoning
 Irritations of nose, throat and eyes

 Sneezing
 Head ache and excitability
 Dizziness and staggering
 Vomiting
 Dry cough and cold sweat
 Drowsiness
 Breathing difficulties
 Pale complexion
 Muscular spasms
Leak detection system
• Fixed monitoring system
• Portable / handheld detectors
HYDROGEN
Hydrogen Is generated from HGU & used in Hydro treating Units.
• Highly flammable and explosive

• Flammable range from 4% by volume (lower flammable limit) to 74% by volume
• Hydrogen flame (or fire) is nearly invisible
• Hydrogen is a simple asphyxiant
• Exposure to high concentrations may exclude an adequate supply of oxygen to the
lungs.
LIQUIFIED GASES (LPG)
LPG Is a product from CDU,DCU & stored in Mounded Bullets.
• Mixture of C3 and C4 hydrocarbons

• Flame may spread rapidly through the cloud from the point of ignition and
complete combustion may take place within seconds
• Flash Fire
• Jet Fire
• Pool Fire
• BLEVE
NAPHTHA AND OTHER HEAVIER HYDROCARBONS
• The major hazards from these types of hydrocarbons are fire and radiation.
• Any spillage or loss of containment of heavier hydrocarbons may create a highly
flammable pool of liquid around the source of release.
S. No Properties Values
1 Flammable Range (%v/v) 0.8 - 5
2 Auto ignition temperature (°C) 228
3 Heat of combustion (Kcal//Kg) 10,100 10100
4 Normal Boiling point (°C) 130
5 Flash point (°C) -21.7 to 42
BENZENE (NHT Feed, CCR , Benzene Recovery Unit , Py. Gas HDT, BTX Units)
• Both toxic and flammable hazards.

• Very low flash point (-11.1°C), indicating that its vapor cloud easily gets ignited.
• The vapor which is about 3 times heavier than air may originate flash fire and
explosions.
• Inhaling very high concentration of Benzene vapors can result in death, while
inhalation of lower concentration can cause drowsiness, dizziness, headaches and
unconsciousness.
• Prolonged exposure period (365 days or longer) may adversely affect bone
marrow and cause a decrease in red blood cells leading to anemia. Benzene is a
recognized carcinogenic.
 Odor threshold - 0.16-320 ppm
 Threshold Limit Value(TLV) - 10
 Short Term Exposure Limit (STEL) (15 Minutes)- 15
 Immediately Dangerous to Life and Health (IDLH) level (for 30 min
exposure)- 500
TOLUENE (CCR , DFCU,BTX Units)
• Both toxic and flammable hazards.

• Very low flash point (4.4°C), indicating that its vapor cloud easily gets ignited.
• Release of Toluene at temperatures near boiling points would lead to formation of
pools and then pool fire.
• Inhaling very high concentration of Benzene vapors can result in death, while
inhalation of lower concentration can cause drowsiness, dizziness, headaches and
unconsciousness.
• Prolonged exposure period (365 days or longer) may adversely affect bone
marrow and cause a decrease in red blood cells leading to anemia. Benzene is a
recognized carcinogenic.
 Threshold Limit Value(TLV) - 10

 Short Term Exposure Limit (STEL) (15 Minutes)- 5
 Immediately Dangerous to Life and Health (IDLH) level (for 30 min
exposure)- 500
AMMONIA (SWS)
The hazard associated with ammonia is both toxic and flammable hazards. Toxic
hazards being more pronounced. Vapors of ammonia may cause severe eye or throat
irritation and permanent injury may result. Contact with the liquid freezes skin and
produces a caustic burn.
Below table indicates the toxic properties of ammonia.

Sl. No. Threshold Limits Concentration
(PPM)
1 Threshold Limit Value (TLV) 25
2 Short Term Exposure Limit (STEL)(15 35
Minutes)
3 Immediately Dangerous to Life and Health 300
(IDLH) level (for 30 min exposure)
SAFETY DURING COMMISSIONING
1. PRE START UP SAFETY AUDIT / REVIEW:
PSSR to be carried out before the plant goes into commissioning stage and all
critical points should be liquidated before feed cut-in. The Pre-startup Safety review
(PSSR) shall be conducted by a review team which will include as a minimum the
following participants
• HSE Engineer
• Process Manager/Engineer
• POSD Engineer
• Representative of owner
• Representative of Licensor – on the basis of contractual agreement
• Any external agency (e.g. third party inspection) if required by owner.
PRE STARTUP SAFETY REVIEW CHECKLIST
The review shall check various aspects of the plant. Typical List of Aspects for
PSSR are as follows:
• Fire Protection System

• Fire/Gas detection System
• Flare & Relief System
• Plant and site layout
• Dyke and drainage and sewer system
• Buildings and structures
• Noise contours
• Safety showers and eye wash fountains
• Protection devices on machinery and individual
• Asphyxia or toxicity in closed environments
• Safety Signs
• Hazardous area classification conformity
• Emergency Shutdown System
• Process Safety Devices,
• Process Safety Information and operating procedure
• Operator Safety Training
• Emergency Planning and response
• Critical tests and checks
• Safe Work Practices
• Maintenance training and mechanical integrity
• Emergency exists availability
• Availability of PPE at site
2.Clear demarcation and signposts shall be made to ensure and demarcate the live
areas of commissioning and the construction areas.
3. It shall be ensured that no longer construction work can be carried out in the
commissioning area without Client’s work permit.
4. It shall be ensured that all relevant statutory certificates are obtained and properly
maintained (e. g IBR, OISD, LPA, etc) before start of the commissioning activities.
5. Before taking Hydrocarbon in ISBL , following system shall be ready
• Gas detection system

• Fire Fighting System & Fire Alarm System
• Utility System
• Instrumentation
• Lighting
• Fire Proofing of structure, cables
• Insulation Work for piping, equipment
General Safety Instructions for Commissioning
• Smoking is strictly prohibited in the operating plant except in smoking booths.
• To obtain necessary safety permit before start of any repair maintenance work.
• Safety Induction is Mandatory for all.
• Operation of machine / equipment by authorized personnel only.
• Use of PPE to comply with.
• Use of only flameproof portable lamps (24Volts) inside tanks / confined locations.
• Follow proper safety instructions according to the chemical's material safety data
sheet (MSDS) supplied by the manufacturer / supplier.
• Use of camera only on authorization.
• Keep plant area clean and free of junk.
• Entry of automotive vehicles in the process area is restricted.
SAFETY DURING MAINTENANCE
It is strongly recommended that detailed maintenance procedures be written down for
maintenance work on each piece of major equipment or processing system. These
should take into account all possible hazards and should include at least the
following general rules:
• Instructions for isolation of process and utility streams, lock-out of electrical

equipment, venting, draining and purging requirements, location of blinds.
• Instructions for sampling the surrounding atmosphere, types of test, permissible
limits for contaminants before and during the work.
• Instructions regarding types of permit required to carry out work.
• Specification of types of maintenance equipment & emergency equipment to be
used.
• Specification of personnel protection equipment required for executing the work.
• Definition of supervisory staff required and designation of individual
responsibilities.
SAFETY DURING MAINTENANCE
Preparation for Maintenance
• Venting and Draining of Equipment and Systems

• Positive Isolation and Purging of Equipment
• Testing of the Atmosphere
Permits
• No maintenance work should be started until a work permit has been signed and
issued by an authorized person indicating that the area to be worked in has been
properly prepared and tested in accordance with standing maintenance
instructions.
•
• Special permits are issued for each work category (hot works, excavations,
electrical works, vessel entry, etc.), with all special requirements for personnel and
plant protection clearly stated. Such permits should be issued for a specific period,
(e.g. to cover one operating shift), and only renewed after full re-inspection of
working area.
GOOD HOUSEKEEPING
GOOD HOUSEKEEPING IS CONDUCIVE TO SAFE OPERATION.
• Paper, wood, waste, and other refuse must be deposited in refuse containers.
• Keep process area, control room and other areas clean and orderly.
• Oil soaked rags and waste may ignite spontaneously; they must, therefore, be
discharged into steel containers specially marked and located for this purpose.
• Access to ladders, stairways, fire escapes, fire extinguishers, steam hoses, water
hoses and hydrants must be free of obstruction.
• Drum, cans and funnels used to dispense lube oil must be cleaned after use and
returned to their proper place.
GOOD HOUSEKEEPING
• Tools, bolts, nuts, lengths of pipe, flanges, etc. must never be left lying on
platforms or walkways.
• Fire fighting equipment is for fire fighting only. Never use it for utility purposes nor
remove it from proper locations.
• Hang hose on rack when not in use. If hose is to be used for extended periods,
string it above walkways to eliminate tripping hazards.
• Never allow any water (rain) accumulation over crossover/ transition or refractory
lined Ducting.
QUERIES
Thank You !

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Engineers India Limited

SAFETY DURING START-UP & COMMISSIONING

08th Jan, 2018

Why Operational Safety

Hazards during Pre-Commissioning

General & Specific site safety procedure

Hazardous Properties of Chemicals

Safety during Commissioning

• An assembly of all systems/ a group of units

• Breaking down of the plant into precisely

• A characteristics of the system/plant process that

• A specific unplanned event or sequence of events

• Risk is the probability that human, Property or the

‘INTRINSIC SAFETY’ REMOVES THE HAZARD ITSELF.

SUBTRACT OPERATION SAFETY

• 48 Dead (official figure)

 Business & reputation (brand, revenue or entire industry sector)

 Management becomes distracted from other aspects of the business

 Management becomes distracted from other aspects of the business

Format A – Internal Intimation regarding system completion

Format B - Internal Check lists

Format-I – Intimation regarding system completion

Format-II– Check lists

Format-III– Ready for pre-commissioning certificate

Format-IV– Ready for Commissioning certificate

Format-V– Successful completion of commissioning certificate

 Inspection of tanks/vessels/columns etc for cleanliness & any other

• Cleaning & flushing of sewer systems & blow down systems.

• Chemical cleaning for pipes / vessels etc as required as per the

• Passivation of lines / vessels / equipments as required.

• Testing of safety valves & other safety devices

• Testing of heat exchangers for leaks

• Checking out interlock systems & emergency shutdown systems

• Installation of temporary blinds / spools to enable isolation of systems

• Refractory drying for furnaces

• Removal of temporary blinds just prior to commissioning

• Loading of catalyst, molecular sieve, packing etc.

• Leak test of vessels / piping /equipments

• Drying of columns / reactors /equipment with dry air / nitrogen as

• De-airing of the systems by nitrogen purging / steaming as required

CHEMICAL CLEANING OF LINES AND EQUIPMENT

• If the chemically dosed water is drunk, it may result in illness or death.

AIR BLOWING OF LINES

• If the line, column is under pressure with a product or substance it will

REPLACING STUDS/BOLTS/ GASKETS/ INSERT OR REMOVE SPADES

ROTATING EQUIPMENT AND OTHER ELECTRICAL TESTING

• There is always a danger of electrical shock and/or unguarded moving

• Failure of instrument system may lead to injuries to persons working

REFRACTORY DRY OUT

• Spillage of Furnace oil, Gas Leak, Fire, Explosion.

• Confinement, Fall of Object, Fall from Height, Chemical Dust

Toxic Materials (H2S,Ammonia,Benzene,Toluene)

Carcinogenic Materials (Benzene, Toluene)

Corrosive (Caustic Soda, Acids)

Flammable & combustible liquids (HC,H2)

RESTRICTED AREAS INSIDE SITE

• Identification of Restricted areas

• Control / guard entry of persons, equipment and vehicles

SAFE TRAFFIC MANAGEMENT

FIRST AID / MEDICAL FACILITIES

List is to be maintained containing Contact numbers of

• Client & EIL site in charges & Commissioning coordinators

BANNERS AND SIGNS