SIMOPS

CONSTRUCTION
COMMISSIONING,
(SIMULTANEOUS
OPERATIONS)
 Introductions
 What is your name ?

 What is your job ?

 Do you have any past experiences involving

Construction/Commissioning SIMOPS?
CONSTRUCTION/ COMMISSIONING & SIMOPS
OBJECTIVES:
TO SAFELY PREPARE THE SITE WORK FORCE
FOR ONGOING CONSTRUCTION,
COMMISSIONING WORK & SIMOPS
CONSTRUCTION/ COMMISSIONING & SIMOPS

TYPICAL ACTIVITIES INCLUDE

• Flushing • Drying out of circuits,
• Chemical Cleaning equipment
• Air Blowing • Filling/ Inventory of Chemical
• Tightness Testing • Introduction of flammable
• Simulation Runs liquids and gases
• Electrical Energization • Nitrogen Purging
• Isolation of live sections
WE COMMUNICATE CONSTRUCTION AND COMMISSIONING
SAFETY INFORMATION TO WORK FORCE BY

• Training Sessions
• Toolbox Talks
• Pre-Task Discussions
• Method Statements
• Risk Assessments
• Inductions

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 TOPIC FOR DISCUSSION

INTERFACE CONTRUCTION/COMMISSIONING
BARRIERS AND SIGNS
COMMISSIONING
TYPE OF ISOLATION

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BARRIERS & SIGNS
• Correct type of safety
tools
• Correct level of safety
(PPE, Tools to safely
execute the Scope of
Work)
• Full face shields during
chemical unloading
 PERMIT TO WORK SYSTEM
• Hot Work naked Flame
• Spark Potential
• Cold work
• Confined Space - Stand by men
• Vehicle Entry (Diesel fueled
+ Flame arrestor)
• Equipment Disjointing
• Authorization / Training

PERMIT AND SIGNATURES ARE NOT FOR

INFORMATION ONLY
Y O U A R E R E S P O N S I B L E!!!
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 TYPICAL SOURCES OF IGNITION
• Welding • Hot Surface Temperatures
• Burning • Non-Intrinsically Safe
• Grinding Equipment
• Soldering • Smoldering Scaffold Boards
• Smoking • Temporary Equipment
• Vehicle Entries (generators, compressors)

CONTROL MEASURE?
 TYPICAL CONTROL MEASURES
• Permit to Work • Emergency Preparedness
• /MOS/TRA (Task Risk (Shower, Eyewash
Assessment) Station)
• MOC (Management of • First Aid Kit
Change) • Detection System
• Barricades/Signs • Energy Isolation-LO/TO
• Communication • PPE
• Competent Personnel • Training
HIGH RISK OF SCOPE WORK INCLUDE
PRESSURE TESTING

Responsible testing personnel:

•attend the system at all times
•constantly monitor the system
 PRESSURE TESTING
Pressure testing equipment:
•fully operational
•regularly maintained
•calibrated
 PRESSURE TESTING
• Warning signs and barriers
• Caution tags to identify equipment and
lines under test.

LEAK TESTING
 PRESSURE TESTING
Pneumatic testing and very high-
pressure hydro testing (HHP) –
• Conducted by Competent Person
• Only Authorized
Personnel in the
vicinity
HAZARDS OF NITROGEN

IT CAN KILL YOU

 Oxygen
Deficient
Atmosphere Nitrogen Leak

Ground Level

Beware of changing fittings on piping being purged with nitrogen, e.g., changing a valve,
turning a spectacle blind, etc.
 ELECTRICAL ISOLATIONS/
RE-ENERGISATION
• Can only be carried out by Authorized Electrical
Person
• Only AEP can isolate/de-isolate electrical
equipment
• Task Supervisor to sign Electrical Isolation
Certificate and witness isolation
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Types of Lock Out Devices
Mechanical isolation used for gas, liquid or vapor:

Spade
 Chemical Handling

• Personal Protective Equipment (PPE)

• Ingestion (Eating, Drinking, Smoking)
• Skin Contact
• Safety Shower, Eye Wash

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 DO NOT OBSTRUCT

- Safety Equipment
Or

- Access/Egress

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 ORGANIZATION SIMOPS
• Principle:
 Construction, Commissioning, and
Production must run together Parallel
operation.
An awareness program on simultaneous
operations (SIMOPS) is crucial for
maintaining a high level of safety in site.
This program ensures that safety
Applied in a Procedure to fix:
measures and protocols are effectively
 Responsibilities
implemented.
 Coordination
 Relationship between
all involved parties
 SIMOPS - Introduction
• Simultaneous Operations (SIMOPS) is when more than one activity takes place in the
same location or area either of which have the potential to seriously / catastrophically
impact the other activities.

Activity # 1 Activity # 2
Risk Identified Risk Identified
Safeguards in place Safeguards in place
 SIMOPS Responsibilities and Main Tasks
• HSE Plan for SIMOPS is required and shall define all
procedures and organization
• HAZID and consequence analysis to be performed
• Risk to be assessed and “Hazard and Risk Register &
Mitigation Plans” to be updated to reflect findings
• Proper Permitting and Control are KEY to Success –
Communicating and Planning (Use PTW to carry out the work)
SIMOPS Responsibilities and Main Tasks, Contd…

• Risk reduction measures to be provided (F&G detection, assets

and personnel protection
• Provide to all persons exposed to a potential H2S risk personal
toxic mask and personal detectors
• All training for SIMOPS must be provided to all persons
working inside SIMOPS area
• Emergency Response Plan during SIMOPS developed in
conjunction with PPCL
 Expected SIMOPs during - 2024
Q2
Q3 Q4 2025
Electrical Fuel Gas In Wet Gas In
Energization 2024 2024
2024

Pre & Commissioning

(Activities 1) •SIMOPS Program
• Pre SIMOPS HAZID SIMOPS Phase • Activity Coord. / Planning
• Safe Systems of Work: (Activities 2) • SIMOPS Areas Maint.
• Hazard & Risk Mgmt. Activities 1, and • SIMOPS / H2S Training
• PTW Implementation • Emergency Response
• LOTO Program • SIMOPS Security
• Confined Space Program
• Elec. Safety / Other Training
• Communications - TBT’s etc.

COMMISSIONING / SIMOPS STARTS

COMMISSIONING SIMOPS PHASE

 SIMOPS Risks – Restricted & Impacted Areas
Electrical Energization ( 2024)
SS02
SS21 SS24 Elec. Energization Phase 1 (Feb)
SS22
• Live Equipment
CCB/SS0
• Live buried services in Constr.
areas
SS11 SS14
• Restricted / Impacted area
MS1/SS1
PER3/PIR3
SS12 Consequence of Live equipment
CCB
Limitations:
SS30 • F&G Systems not fully
MSS
TR34
operational
Apr-24 May-24 Jun-24 Jul-24 Aug-24 Sep-24 Oct-24 Nov-24 Dec-24
• Electro Magnetic doors not fully
PER1/PIR1 operable
• Mark underground electrical
PER2/PIR2 power – stakes etc.
• PTW for all excavations
 SIMOPS Risks – Restricted & Impacted Areas
Temporary Fuel Gas (during 2024)
Fuel Gas Phase 1 (June)
• Dispersion of Flammable Gas
and jet Fire
Temporary Fuel Gas Line
• Restricted / Impacted area
Consequence of a lower
flammability limit (LFL) (LEL)
Temporary FG Vent • Impacted Area
Limitations:
• Model assumes 2 automatic
2024 2024 2024 2024 2024 2024 2024 2024 2024
ESD in series
• Manual ESD Results in
increased duration and area of
release
• To be included in further
modelling
 SIMOPS Risks – Restricted & Impacted Areas
Fuel Gas In (during 2024)
Fuel Gas Phase 2 (during
2024)
ESD: Automatic / Manual,
item Phase 1;
ESD locations: extension of
The lower flammability limit
(LFL) compared to Phase 1;
Potential Impact of
Temporary Fuel Gas Line
Uncontrolled Lifting
(Removal once permanent
lines live in 2024) Temporary FG Vent
Operations.
2024 2024 2024 2024 2024 2024 2024 2024 2024
 SIMOPS Risks – Restricted & Impacted Areas
Fuel Gas In Units (2024)
Fuel Gas Phase( 2024)
ESD: Automatic / Manual,
item Phase 1;
ESD locations: extension of
The lower flammability limit
(LFL) compared to Phase 1;
Potential Impact of
Uncontrolled Lifting
Operations.
(THIS SECTION TO BE UPDATED TO
REFLECT THE ADDITIONAL
2024 2024 2024 2024 2024 2024 2024 2024 2024 HAZARDS FROM FG WITHIN FIRE
ZONES)
  SEGREGATION PRINCIPLE

For each step on

 SIMOPS Restricted area physically segregated by Fence

At Systems boundaries, Mechanical or Electrical Isolation

 Spading Blinding Plan

 Electrical Isolation

 Instrument Isolation
 CONTROL PRINCIPLE

Typical Segregation method Control Principles by fence or barriers

 SIMOPS Leader: Coordination of Activities

 Permit to Work System & Permit to Work Controllers

 Access Control by Permit, Badges & Security at Access Points

 Safety Supervision (Const./Comm. and Prod. merged)

 Check List and Audits

 Training
 TRAINING

TRAINING
Training helps Coordination of Activities

 Access Control Alarm Evacuation and Mustering

 Work Permit

 H2S

 Hydrocarbon risks

 Fire & Gas Alarm

 Recommendations
• STAY AWAY FROM PIPES UNDER PRESSURE!!!
• Fence and barrier the area
• Post-high-pressure pipes warning signs.
• Inform all people involved and perform toolbox talks.
• Try to position in a safe and resistant way gauges, meters and
all other instruments that are periodically checked during leak
test, in a way that they are as remote from the pipe
as possible.
• Secure all hoses with whip.
 EMERGENCY PREPAREDNESS
On Hearing The Siren, You Should……

• Stop work immediately

• Switch off and isolate/depressurize supply to any equipment in

use, if possible, without putting your life in danger!

• Check wind direction (windsock)

• Proceed to Assembly Area (Safest Muster Point)

 EMERGENCY RESPONSE
• On discovery of fire or any emergency situation….
• Raise the Alarm! (PA/GA System, Manual Call Point “HSK”)
• Fire Alarm (5sec. on, 5sec off) - Yellow Flashing Light
• Toxic Gas Alarm (1 sec. on, 1 sec. off) – Red Flashing Light
• Evacuation (Oscillating tone) – Yellow & Red Flashing Lights
• Inform HSE & Security
• If Not proceed to Muster Area (by using wind direction)
 EMERGENCY REPORTING
• The following information is needed while making
an emergency report:
– Location of Incident
– Type of Emergency
– Number of Casualties
– Your Telephone Number
– Your Name & Company
 Lesson Learnt
Position of mechanical plug before
incident

Position of mechanical plug after the

incident
Lesson Learn
Lesson Learn