management of change

COMPANY MANAGEMENT SYSTEM

(Management Of Change)

Issue: A

Rev No: 1

Doc No: SCU(S)/MS/13

Page: 1 of 37

TITLE: MANAGEMENT OF CHANGE

Issue No. Revision No. Description of Change Effective DateA 0 First Issue

1

REVISION HISTORYINTERFACE DOCUMENTSDocument Number: Document Title:SCU(S)/MS/08 HSE Management SystemCode of Practice Safety Management System for Chemical IndustrySCU(S)/MS/06 Regulatory ComplianceDISTRIBUTION LIST Department Controlled

Copy no.Recipient Department Controlled

Copy no.Recipient

Seraya Ops 01 Ops Mgr. Sales & Mkt 10 HOD

Power / Utilities Ops

02 Ops Mgr. Finance 11 HOD

SembGas 03 GM Risk Mgt 12 HODCFD 04 Ops. Mgr HR 13 HODTechnology 05 HOD Legal 14 HODHSE 06 HOD IT 15 HODMaintenance 07 HOD. Comm & Trd 16 HODProjects 08 HOD Matl. & Svcs 17 HODAM Optimization 09 HOD QA & QC 18 HOD

DOCUMENT OWNERSHIP

Details Departments

Business Process Owner

Optimisation

Key Users Operations, Projects, Maintenance, HSE, QA/QC

APPROVAL

Prepared by: Reviewed by: Approved by:

Name: Name: Name:

Designation:)

Designation: Designation:

Signature: Signature: Signature:

Date: Date: Date:

CONTENT



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SECTION DESCRIPTION

REVISION HISTORY

REFERENCE DOCUMENT

DISTRIBUTION LIST

DOCUMENT OWNERSHIP

APPROVAL

1. PURPOSE OF MOC

2. SCOPE

3. DEFINITIONS & ABBREVIATIONS

4. PROCEDURE DETAILS

5. ROLES & RESPONSIBILITIES

6. BUSINESS RULES, CONTROLS, LEGAL & SAFETY REQUIREMENT

7. APPENDIX

1.0 PURPOSE

To establish a systematic evaluation of hazards and risks associated with new facilities, changes and modifications to plant and equipment so that these changes achieve their purpose without compromising the operations, maintainability, reliability, HSE and contractual aspects.

To serve as a means of documenting the modifications & changes to the plant facilities / equipment and provide traceability to the physical and documentary updates.

2.0 SCOPE

This procedure shall apply to

All modifications on plant, buildings, services and equipment on SCU (Singapore) plant facilities, except where these fall under the exemption list below.

large scale modifications, retrofits or new facilities which are managed as projects (the requirements of MOC has been incorporated into CMS/SCI(SUT)-PD-001 Projects Management Procedure)

modifications on third party lines in Service Corridor

This procedure shall not apply to the use of new hazardous substances on site which is not in conjunction with any other modification or process / plant changes or new facility; the control of which is addressed in HSE/SOP/006 (Control of New Hazmat)

3.0 DEFINITIONS



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3.1 Changes & modifications subjected to MOC:

3.1.1 Any change in the approved method of operation (the approved method of operation should be set down in Standard Operating Procedures).

3.1.2 The introduction of any new substance into any part of the process or plant equipment.

3.1.3 Any change to buildings, or erection of temporary buildings/accommodation, structures, pipelines, corridors, drains, roadways or which could affect their fitness for purpose or the safety of personnel who work in or around them.

3.2 EXAMPLES OF MODIFICATIONS / CHANGES SUBJECTED TO MOC

3.2.1 A change from the existing design (P&I diagram) of the relevant section of plant.

3.2.2 A change in material of construction, size or shape of any component which is in contact with process fluids, steam or piped services or which could affect the flow, temperature, pressure or composition of such fluids

3.2.3 A repair to an existing item of equipment or plant component, which require changing the existing design.

3.2.4 Introduction of a new waste stream at WWT or at incinerator or a change in the fuel at the boilers

3.2.5 Any change to the amounts or composition of emissions or discharges or any change to the means of generation of toxic wastes

3.2.6 Changes to the process control computer’s software or hardware. Change of control logic on DCS

3.2.7 A change in equipment design, layout or materials of construction.

3.2.8 A change to the setting of trips, alarms or relief devices outside approved operating experience.

3.2.9 A change to any plant protective system such as deluge systems, smoke, heat, toxic gas detectors, any other safety systems which are installed for personnel/equipment protection.

3.2.10 A change to plant/office layouts which involves doors/means of escape/fire fighting equipment or the installation of temporary or permanent portable cabins, or any other change which affects the fire safety systems covered by the Fire Certificate.

3.2.11 A change in Pipe Bridge or corridor due to addition or removal of pipe

3.2.12 Any change in the plant layout which affects the Factories License and notification to MOM.

3.2.13 Demolition of plant and equipment

3.3 Exclusions



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Changes specifically excluded from the MOC are:

3.3.1 Process changes within the approved method of operation.

3.3.2 Replacement of a plant hardware component by a new component of identical design, i.e. a repair.

3.3.3 Tuning of instrument controller terms, (P, I, D, etc) that fall within process parameters. These are not considered to be modifications, but should only be made by competent Instrument/Electrical personnel.

3.3.4 Purchase of new hazardous substance for use in the new modification.

3.4 Temporary MOC

Temporary repairs e.g. injecting quick setting epoxy resins into leaking joints, clipping, etc which may be an acceptable temporary standard in certain duties will be captured by temporary MOC for monitoring the reinstatement of the repair to the original design standard. The circumstances and conditions under which such a repair may be carried out shall be clearly specified in an established maintenance procedure and the repair shall be authorized by a nominated engineer.

SINGAPORE OPERATIONS



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4.0 PROCEDURE DETAILS

4.1 FLOWCHART

Control of construction phase, checklist for compliance before approving commissioning and starting up.

Control of Process Definition & design to accommodate impacts on Safety, Operability, Environment, Maintainability

MANAGEMENT OF CHANGE FOR PLANT FACILITIES PROCESS FLOW

PROJECT BASED MOC

Incorporated into Project Mgt System 4

PART 1 OF MOC

EMERGENCY

PART 2 OF MOC PART 3 OF MOC

Control of updating of plant technical information

Operation Mgr

Proceed withModification

Commissioning I/C

Fill up Part 2 MOC before Commissioning

13 MOC Leader

Coordinate updating of plant technical documentations & records. Using Part 3 MOC

Checklist as a guide (Appendix 7)

NO

8 Optimization HOD

Appointment of Commissioning In Charge by the Optimization HOD

9 Operation, QA/QC, Safety & Maintenance

Use MOC’s Punch listing Guidelines (Appendix-5) to conduct walk down together and comment

10 Commissioning I/C

Run through Part 2 Pre-commissioning checklist (Appendix 6) to verify readiness of modifications to

be commissioned.

11 Commissioning I/C

When all category A punch lists are rectified, Part 2 Pre-com checklist is satisfied, multi-disciplinary HOD

will sign off Part 2 MOC form in Appendix 2.

12 Operation Manager

Operation manager will give final sign off to approve commissioning

PROJECT BASED

OPERATION BASED

14 Optimization & Operation

Multi-disciplinary HOD will sign off the Part 3 MOC Form in Appendix 3 to close out MOC and

operations to take over

15 MOC Leader

MOC leader will arrange the completed master copy of the modification form to be submitted.

Optimization HOD will update the MOC Register in Appendix 8

Next Next

1 Initiator

Proposes change/modification to his supervisor/operation manager

2 Operation Manager

Evaluate the proposal and either agrees & passes it optimization or rejects & passes it to initiator

3 Optimization HOD

Appointment a MOC leader to conduct multi-disciplinary evaluation

4 MOC leader

Conduct multi-disciplinary evaluation using Part 1 Checklist provided (In Appendix 4), review DBM, detail engineering & scope of work

6 Operation Manager

Raise capex if necessary

5 Optimization & Operation

Appoint project team (either from maintenance or project team depending on the change) to finalize design & get estimated cost

Review & give final approval to start construction

7 HSE, QA/QC, Maintenance, Optimization & Operation

YES

Prepare DBM

1 Process Engineer

Review & give final approval

2 AM, QA/QC, HSE

Raise MOC to register the change using part-1

and close it after MC

3 Projects




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4.2 FURTHER DESCRIPTION TO THE FLOW CHART

Flow # Further Description to the Flowchart

PART 1 OF MOC

1. The person who proposed the modification or change shall seek the Unit Supervisor for discussion & evaluation of the feasibility

2. Initiator shall submit request of change / modification to Opn Manager to evaluate. Operation Manager agrees to proceed further.

3.

3.1 Operation Manager to forward the details to optimization if agree to proceed. MOC leader shall be appointed from the Optimization department by the HOD to conduct multi-disciplinary evaluation exercise using Part 1 Design Review checklist provided. (See Attachment , Appendix 4)

3.2 MOC Leader shall issue a unique reference number to the MOC, as follows

N-MOC-YY/XX, where

N = 1 (Power / Utilities), 2 (CFD), 3 (Seraya), 4 (Sembgas)

XX = 2 digit running number, YY = year3.3 MOC Leader should be someone who is most familiar with the Unit facility.

4.

4.1 MOC Leader shall use Part 1 MOC Checklist (Appendix 4) to assess safety impacts, new risks, side effect on process, maintainability and operability.

4.3 In doing so, he shall jointly complete the checklist with the relevant disciplines, such as HSE, Maintenance, Operations, QA/QC etc

4.3 The Part 1 MOC Checklist shall be used for these 3 aspects of the Design Phase reviews: - Design Basis memorandum review, Detailed engineering review, Scope of Work review.

4.4 Optimization HOD shall appoint a Project I/C or Coordinator. All feedbacks & concern from Part 1 MOC evaluation shall be analysed and categorized into the following aspects

Safety / Reliability / Regulatory / Maintainability / Cost savings to facilitate prioritization

5. Project Team (appointed on case to case basis either from Maintenance or from Projects) shall finalize design & get estimated cost from Vendors.

6.Operation Manager shall raise Capex if necessary

7.

7.1 Only when Part 1 checklist has been signed off by all relevant department heads (Operations, Maintenance, QA/QC, HSE & Optimization) can the construction phase commence.

7.2 Once top management has given Capex approval - Operation Manager and Optimization HOD shall sign off Part 1 of MOC so as to give final approval for start of procurement, fabrication and construction of modification.

7.3 The final modified PIDs drawing shall be then stamped with a “Approved Forr Construction” by the Optimization HOD

7.4 The project schedule & milestones can be drafted depending on the nominated project leader - and all this should synchronize with the Operation schedule.

PART 2 OF MOC




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8.Optimization HOD shall appoint a Commissioning In Charge I/C

9.

9.1 Commissioning IC shall use Punchlisting guidelines to conduct Walkdown for Operations together with Maintenance, QA/QC & HSE (See Appendix 5 for Punchlisting Guidelines).

9.2 On completion of the fabrication/construction work, the Operations & Mechanical Manager shall ensure that the work is thoroughly checked and punchlist is carried out at 80% & 100% mechanical completion stages.

10.

10.1 After O&M Punchlisting is completed, the Commissioning I/C shall follow up on CAT A punch list and all issues & concerns shall be rectified.

10.2 Run through Part 2 Pre-Commissioning checklist (Appendix 6) to verify readiness of modifications to be commissioned.

10.3 Once the Checklist verifies that the system is ready to be commissioned, Part 2A MOC form (Appendix 2) shall be filled which signifies permission to commission the modification.

10.4 If the modifications are to be commissioned in stages, then fill up Part 2A, 2B of the Form and attach a commissioning procedure showing different stages of the commissioning stages. Each stage shall be signed off before proceeding to the next stage. Part 2B form provides a means to sign off individual stages.

10.5 Once the modifications are completed, Part 2C shall be signed off.10.6 Part 2D is for temporary modifications. The Operation Manager shall also record

in Part 2D, at the time commissioning- the date when the temporary modification is expected to be removed. In the case of temporary modifications, Part 2A, 2B, 2C & 2D shall also be filled.

11. Operations, Maintenance, QA/QC, HSE and Optimization HODs shall sign off the Part 2 MOC, after assisting the Commissioning I/C to verify status of modifications.

12. Operation Manager shall give final sign off to approve commissioning. No commissioning is allowed until Part 2 MOC control form (Appendix 2) is fully signed off.

PART 3 OF MOC

13. The MOC Leader shall coordinate & facilitate the updating of the technical information and relevant records.and complete Part 3 MOC checklist.

14.

14.1 When updating is completed Part 3 shall be signed and dated by Heads of Operations, Maintenance, QA/QC, HSE and Optimization; as evidence that all relevant documentations in all departments are updated – so that the MOC is satisfactorily closed out.

14.2 MOC shall remain open until all outstanding issues have been resolved.

15.

15.1 MOC Leader shall arrange for the completed master copy of the modification form and updated drawings to be given to Optimisation HOD.

15.2 Optimization HOD shall update status of MOC created periodically to management by completing the MOC Register ( See Appendix 8)

15.3 On a regular basis, the Register shall be used to counter check the validity of the P&IDs, SOPs and other technical documentation.

15.4 When the Document Control Centre (i.e. the library) is set up, all master copy of MOC including updated drawings shall be kept at the Document Control Centre.

4.3 EMERGENCIES




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4.3.1 In the event of any emergency, the repair and restoration of the plant shall take precedence

4.3.2 However Part 2 (Pre commissioning Checklist) shall be filled up before the commissioning to ensure safety and integrity of the modifications.




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RESPONSIBILITY MATRIX

Flow ActivitiesMOC

InitiatorOps

ManagerOptim HOD

MOC Leader

Project Team

Comm I/C

HSE Maint QA/QC

1 Propose the change/modification X

2 Evaluate and recommend or reject X

3Approve MOC, appoints MOC Leader, assign MOC reference number

X

4 Conduct multi disciplinary checks O O O X O

5 Finalize design and get cost estimates from vendors O O O X

6 Obtain capex approval X O X

7 Final approval to proceed with implementation/construction X X X X X

8 Appoint Commissioning IC X X X

9 Use punchlist guidelines to conduct walk down X O X O O O

10 Run through Pre Commissioning check list O X X O

11 Approve for commissioning X X X X X

12 Coordinate updating of plant technical documentation X X

13 Close out MOC by signing off Part 3 MOC O O X X

14 Update MOC Register X

X – Lead O - Support




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5.0 ROLES & RESPONSIBILITIES

OPERATIONS

5.1 MOC Initiator – Person who proposed the change or modifications

5.2 Operation Manager Assess all proposed modifications and recommend to optimization to proceed or

rejects and send to initiator Allow to work based on Part – 1 MOC checklist and evaluation Ensures commissioning procedures, start-up procedures, emergency shutdown

procedures are completed before allowing the modified system to be brought alive

5.3 Optimization HOD Appoints suitable, relevant experience person as MOC leader to undertake the

modifications Implement and maintain the MOC system Update MOC register and brief management on the status of the various MOC on

a regular basis

5.3 MOC Leader Person appointed by the Optimization manager to coordinate & oversee the MOC

completion. Conduct multi disciplinary checks and control quality of modifications and new

facilities by complying to the MOC requirements Ensure that all checklist and control forms are filled at each phase of Project Life

cycle before he authorise the next phase. Ensure the person filling the checklist is the persons with the relevant experience,

authority and expertise.

5.6 Project Team – Persons appointed to lead the modification project. He can be either from Maintenance and or Projects Department.

5.7 Maintenance

Participate in the MOC process Comment on the maintainability and workmanship of the completed modifications Ensures all maintenance-related documentation are updated at the end of the

modification

5.8 HSE Participate in the MOC process, comment on the safety, health and environmental

impacts of the proposed changes or modifications Advise on the regulatory requirements and the type of risk assessment required. Conduct independent audits, on a regular basis to ensure compliance to this

procedure

5.9 QA/QC Participate in the MOC process, comment on the inspection, test plan, quality of

the proposed changes or modifications Advice on the regulatory requirements and the type of risk assessment required. Conduct independent checks on a regular basis to ensure quality is ensured

6 DELIVERABLES / OUTPUT




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S/N DESCRIPTION SUBMIT BY SUBMIT TO FREQUENCY

1 MOC Checklist MOC Leader Ops Manager & Optimization HOD

Ad hoc

2 MOC Form MOC Leader Ops, Maint, HSE, QA/QC & Optimization

Ad hoc

7 INTERFACES WITH OTHER DEPARTMENTS’ PROCEDURE

Flow #

Business Process Owner

Doc no.Document Title

2,4 Projects SCU/MS/04 Projects Management

8. AUTHORISATION LIMITS

Flow # Approval on Approving party Limit

NA NA NA NA

9.0 BUSINESS RULES, CONTROLS, LEGAL & SAFETY REQUIREMENT

All authorized Permit Issuer and Shift Managers shall ensure that no unauthorized

modifications are implemented on their plants.

No permits shall be issued for modification work on plant facility – unless Part 1 of this

MOC form is attached. This includes modification on third party lines in Service Corridor

In emergency cases, work can be undertaken on offline plant as long as adequate risk

assessment has taken place, but prior to commissioning a modification, Part 2 shall be

completed.

10.0 APPENDICES

7.1 Appendix 1 - Part 1 MOC Form



7.4 Appendix 4 - PART 1 MOC CHECKLIST (for Design review)

7.5 Appendix 5 - Punchlisting Guidelines




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7.6 Appendix 6 - Part 2.0, Part 2.1, Part 2.2 MOC Checklist (for Pre-commissioning Check)

7.7 Appendix 7 - Part 3 MOC Checklist (for Documentation & post implementation verification)

7.8 Appendix 8 - Register of MOC




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MOC NUMBER: (N-MOC-YY/XX) _______________

N=1 PU, 2 CFD, 3 Seraya, 4 Sembgas, XX=serial number

APPENDIX 1

PART 1 MOC FORM MOC No: PTW No:

BUSINESS UNIT / FACILITY:

MOC LEADER (Person assigned tofill this

form) :

DATE:

DESCRIPTION OF CHANGES:

INITIATOR: DATE:

a) Is this area affected? Is information and/or modified flowsheets/drawings included?

Affected? Attached?YES NO YES N/A

As built PIDsElectrical Schematics & DrawingsControl Systems Configurations drawingsShutdown Matrix TableLadder logic changes?Safety Valve Data (nameplate data, i.e., size, set pressure, and calculations)New Pressure Vessel/Pressure System Ratings

a) List Line PID diagram number. All relevant drawings and information must be referenced and attached to this document. Also sketch the modifications below showing before and after layout.

b) Specify any checks or procedure (Equipment efficiency/ performance guarantee test, third party calibrations certifications, pressure test, NDT tests, stress relieving etc) required during construction to ensure that the design intent has been met.

Details:

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________




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1.0 JUSTIFICATIONS

1.1 Is the proposed work a corrective action as a result of an incident or Root Cause Analysis Report? Y/ N/ NA

1.2 Is there a RCA report no. Or Incident report no. to refer to? Y/ N/ NA

1.3 What are the benefits of the proposed modification? ECONOMIC ($ savings, productivity gains) OR QUALITATIVE (safety environmental, product reliability, product integrity)

REASON for CHANGE/ADDITION/DELETION (provide sketch to help explanation if possible)

COST ESTIMATE OF PROPOSED WORK

SAFETY & PRODUCT INTEGRITYBased on the review of the MOC Parts & Checklist, write down the safety or product integrity concerns that apply to this MOC and the recommendations.

The signature below means:

THE DESIGN REVIEW HAS BEEN DONE BY APPROPRIATE AND EXPERIENCED PERSONNELS AND ALL CONCERNS WILL BE FOLLOWED UP ACCORDINGLY. PART 1 CHECKLIST HAS BEEN COMPLETED AS PART OF THE REVIEW.

ENGINEERING DESIGN OF THE MODIFICATION PROJECT HAS BEEN ADEQUATELY SPECIFIED, SUCH THAT FABRICATION, CONSTRUCTION MAY PROCEED WITH DRAWINGS ATTACHED STAMPED “APPROVED FOR CONSTRUCTION”

*Operation Manager *HOD, HSE *HOD, Maintenance *HOD, Optimization

Sign/Date Sign/Date Sign/Date Sign/Date

*Vetted & endorsed by persons

*Name/Sign/Date required.




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APPENDIX 2

PART 2A MOC FORM - PERMISSION TO COMMISSION (CONTROL OF CONSTRUCTION)

1. This signature means that the new modifications has been fully constructed and satisfactorily tested in terms of operability, maintainability and safety. All required Checklist (Part 2.0, Part 2.1, Part 2.2) has been filled. All CAT A punchlist has been cleared. The modification is ready to be commissioned. A commissioning procedure will be followed. Y/ N/ NA

2. This signature means that the new modifications has been fully constructed and satisfactorily tested in terms of operability, maintainability and safety. All required Checklist (Part 2.0, Part 2.1, Part 2.2) has been filled. All CAT A punchlist has been cleared. The modification is ready to be commissioned in stages. The stages will be explained in attachment; each commissioning stage will be signed off by the Operation manager before proceeding to next stage. Y/ N/ NA

Signed: _________________ Date: ___________

By Project Leader

Signed: _________________ Date: ___________

By Commissioning I/C

Signed: _________________ Date: ___________

By QA/QC

Signed: _________________ Date: ___________

By Maintenance Manager

Signed: _________________ Date: ___________

By HSE Manager

Signed: _________________ Date: ___________

By Operation Manager

*If modification can be commissioned in 1 stage, fill up 2A and 2C only.*If modifications are to be commissioned in many stages, fill up 2A, 2B, 2C. Procedure attached.*If the modification is temporary: then fill up Part 2A, 2B, 2C & 2D as well,




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PART 2B FORM - COMMISSIONING IN STAGES

If this modification is to be commissioned in stages. The section below shall be completed for all stages before the final stage. When part 3C shall be completed. There should be an attached commissioning procedure to this form to explain the stages.

A signature indicates: 1. The break-in or defined part of the modification has been completed and installed in accordance with the design Intent.2. The appropriate pre-commissioning check list has been actioned.

Define part modification to be commissioned:

OPN MANAGER (Name/Sign/Date): _______________________

MAINT MANAGER (Name/Sign/Date): _____________________

PROJECT LEADER (Name/Sign/Date):_____________________

THIS COMMISSIONING STAGE WITH REFERENCE TO ATTACHED PROCEDURE WAS DONE ON (DATE) ____________

BY COMMISSIONING SV/ TECHNICIAN (NAME/ SIGN) _____________________

Define part modification to be commissioned:




THIS COMMISSIONING STAGE WITH REFERENCE TO ATTACHED PROCEDURE WAS DONE ON




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(DATE) ____________

BY COMMISSIONING SV/ TECHNICIAN (NAME/ SIGN) _____________________ Define part modification to be commissioned:




THIS COMMISSIONING STAGE WITH REFERENCE TO ATTACHED PROCEDURE WAS DONE ON (DATE) ____________

BY COMMISSIONING SV/ TECHNICIAN (NAME/ SIGN) _____________________

PART 2C MOC FORM – COMPLETION OF COMISSIONING COMMISSIONING Supervisor (Name/Sign/Date) _______________________________

The entire modification has been commissioned on on (date)____________________

PART 2D MOC FORM - TEMPORARY MODIFICATION

Modification removed on _________________DATE_________

To be put back to Original state on ______________DATE _______

OPERATION MGR (Name/sign) ____________ DATE_______




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APPENDIX 3

PART 3.0 MOC FROM - CLOSE OUT REPORT



OPERATION MANAGER:

FACILITY OR PLANT NAME:

SBU:

*PART 3.0 MOC CHECKLIST (Appendix 7) MUST BE COMPLETED BEFORE THIS MOC CAN BE CLOSED.

This form should be filled within 30 days after the modifications are completed.

1. This signature means that all outstanding issues & work regarding the modification has been addressed, the modification has satisfactorily serves its intent and purpose. All records and documentations are updated accordingly.

2. This signature means that all outstanding issues & work regarding the modification has been addressed. . All records and documentations are updated accordingly. However, the modification has not fully satisfactied its original intent and further monitoring and rework may be required within _________months.

If the box 2 is ticked, please provide details on above:

_________________________________________________________________________

CLOSURE APPROVAL

Signed: _________________ Date: ___________

By Maintenance Manager

Signed: _________________ Date: ___________

By QA/QC Manager

Signed: _________________ Date: ___________

By HSE Manager

Signed: _________________ Date: ___________

By Operation Manager

Signed: _________________ Date: ___________

By Optimization




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APPENDIX 4

PART 1 MOC CHECKLIST (DESIGN REVIEW)

This Design Review checklist covers the Design Basis (DB) and Detailed Engineering (DE) stages. Each stage should be signed off accordingly. This will assess the viability of the proposed modifications from the various aspects such as safety, operability, maintainability, hazards. The assessment should be done by experienced personnels with relevant knowledge and experience. They will mark the Checklist below. Any critical concerns should be explained in details in the last comment box below. The concerns should be addressed at the design phase of the project life cycle. This will avoid unexpected design problems later - which will lead to variation order, punchlists, disputes etc.

DB = Design Basis Review DE= Design Engineering Review1.0 HEALTH , SAFETY AND ENVIRONMENTAL (Responsible Group(s) for Consultation: HSE) Y N NA STG

1.1 PERSONNEL HAZARDS - Do the modifications create any unusual exposure to personnel from: flame, noise, heated or cold surfaces, electrical hazards, toxic or flammable gas leaks, cryogenic leaks? Can the design be changed to minimize the possibility of such exposures?

DB

1.2 Are additional engineering controls required (shielding, fans, ventilation, continuous gas monitors, alarms, remote indication)?

DB

1.3 OCCUPATIONAL HEALTH AND SAFETY REGULATIONS - Has a review been made of any HSE regulations (factories Act, EPCA etc) that may apply to this modification?

DB

1.4 STATUTORY COMPLIANCE - Need to consider compliance to MOM regulations, NEA requirements etc? Require consideration of the relevant Codes of Practice and Specifications?

DB

1.5 RISK ASSESSMENT - Is Hazard review (QRA, HAZOP, Job Safety Analysis, Risk matrix) required? DB1.5.1 Has the risk assessment considered the site changes and any new exposures to the public? DB1.6 LARGE STORAGE TANKS - Does the site modification involve the addition of large storage tanks that

could create an off-site risk if a leak or spill occurs? Are tanks containing flammables being added to the site?

DB

1.7 FIRE PROTECTION SYSTEMS – Is there any changes to the existing fire protection system or are any new fire protection systems required in accordance with good engineering practice or local building codes? Has the SCDF been notified of any changes or additions to the site fire protections systems?

DB

1.8 CONFINED SPACE REQUIREMENTS – Sometimes we need the contractor to provide special safety requirements such as full time site safety officers , or lifting supervisors,or Confined space attendents, continuous gas monitoring portable devices near hot work area, adequate ventilation blowers etc; we need to inform or specify in Scope of Work for contractors. This will allow them to budget and plan for the requirements. Otherwise, they will find it unviable to comply. Is the inclusion into Scope of Work necessary?

DE

1.9 EQUIPMENT LAYOUT – Sometimes piping and equipment layout can cause maintainability or operability problems. Best way to avoid is formally inform the contractor upfront on layout quidelines and best practices. Make it mandatory for the contractor to submit the Isometric drawings to the Unit Opn supervisors for signature endorsement before fabricating. The O&M SV must visit the site itself to physically check against the isometrics drawings before endorsing it. The principle here is to avoid tripping hazards and overhead obstructions unnecessarily; while ensuring ergonomically easy access to important valves and equipments for operation and maintenance. When the layout is congested, have steps, walkways, walking surfaces, signposts, sufficient lighting to ensure that personnel do not become exposed to ergonomic hazards. Is this required?

DE

1.10 NOISE - Will noise levels increase? Have mitigation methods been considered (lagging, noise curtains, barriers, vent or in-line silencers, enclosures, levels at plant boundary)? Is the cost for noise mitigating devices such as noise hoods factor into the modification Budget?

DB

1.11 PLATFORMS, HANDRAILS Will the addition require the installation of equipment to work at elevations or gain access to the modification at unsafe heights? Check the requirements for additions of platforms, handrails, guard rails, ladders.

DE

1.12 BARRICADES - Are barricades, machine guards, bump posts, chain guards to restrict access, or railings needed?

DE




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1.13.1 CHEMICAL USE - Will new chemicals (including catalysts) be brought onsite? DB1.13.2 Will the volume of existing chemicals stored onsite increase? DB1.13.3 Will there be new or increased sources of oil created, e.g., compressors, expanders, machinery? If so,

changes in chemical inventories may need to be reported to government agencies and emergency response agencies. Site emergency and spill contingency plans may need to be modified.

DB

1.13.4 Has the MSDS been considered for the affect on handling, design for maintenance, or installation methods?

DB

1.13.5 Flammable material – Are any new flammable materials to be introduced. Does any licence required by SCDF?

DB

1.14 RESPIRATORY PROTECTION Is additional respiratory protection required because of personnel hazards created by air contaminants released or created during installation, startup, normal operation or maintenance of the modification?

DB

1.15.1 PROCESS AND UTILITY VENTS – Will there be any new vents being added to the site? DE1.15.2 Have these been considered for proper location and size to prevent the formation of a hazardous

atmosphere in the working areas? DE

1.15.3 Is vent location, elevation adequate to prevent exposure to personnel? DE1.15.4 If The vent is a flammable vent stack, an analysis of heat radiation from the stack must be performed to

ensure personnel are not exposed to unsafe levels of heat.DE

1.15.5 Are any new ladders, platforms, or walkways being located where personnel could be exposed to a hazardous release from existing process and utility vents?

DE

1.16.1 DEMOLITION - Will the change require demolition of equipment? DE1.16.2 Will this cause any specific health or safety problems as a result of contained materials being released or

discharged during demolition (asbestos, mercury, lead, catalyst dust, rockwool fibers, etc.)?DE

1.16.3 Is monitoring required to assess exposure during the demolition process? DE1.17 SYSTEM ISOLATION - To accomplish the tie-in of the new equipment to the existing system, determine if

the proper systems isolation can be accomplished in accordance with lockout-tagout procedures. Will additional valves, blinds, or vent be needed to perform safe maintenance of the system?

DE

1.18 DISPOSAL - Will demolition or disposal of any of the unused equipment create special health or safety hazards that must be considered in the change?

DE

1.19.1 LIFTING DEVICES - Have cranes been considered for the removal of heavy objects? DE1.19.2 Do the lifting devices meet safety standards? DE1.19.3 Check capacity, stability, location, etc. Is lifting Supervisor required during the construction? DE1.19.3 Do we need to put this requirement in the Scope of Work? DE1.20.1 PROCESS, SANITARY, HYDROSTATIC TEST WASTEWATER - Will any new discharges be created? DB1.20.2 Will any existing discharges be modified (volume, cooling water chemistry, chemical content, increase in

cooling tower cycles of concentrate, location of discharge point)? If so, permits or permit modifications may be required.

DB

1.21 CHEMICAL AND PRODUCT STORAGE TANKS - Does the storage involve the installation of aboveground or underground tanks (for chemicals, lubes, products, and byproducts)? If so, proper containment and leak detection monitoring must be provided and the site emergency and spill contingency plans may need to be modified. Registration of tanks with agencies may be required. Changing raw materials stored in existing tanks may require agency notification. (UNDERGROUND TANKS SHOULD BE AVOIDED!)

DB

Y N NA STG

1.22 INDUSTRIAL WASTE 1.22.1 Alter the amount, composition or means of disposal of effluent? DB1.22.2 Will any new or increased waste streams be created? DB1.22.3 Will construction/demolition waste, asbestos waste, tank clean-out waste, excess freons, PCBs, catalysts,

paint wastes, blast material with paint chips, or other waste chemicals or oils be generated as a result of the project? If so, waste testing, disposal arrangements, and waste registrations may be required.

DB

1.23 RADIOACTIVE MATERIALS - Will any new sources of radioactive materials be created, e.g., analyzers, special level gauges, etc.? If so, registration of materials with government agencies may be required.

DB

1.24.1 EXCAVATION/FILL MATERIALS - Will excess excavation fill be generated? Will this fill be hauled offsite? DB1.24.2 If so, an evaluation of suspected soil contamination may be required prior to offsite disposal. Will fill

materials be brought onsite? If so, an evaluation of the source may be required to prevent contaminated fill from being brought onsite.

DB

1.25 ENVIRONMENTALLY-FRIENDLY CHEMICALS - Have any new chemicals been reviewed to select the most environmentally-friendly substitute? Chemicals to avoid include certain freons (CFCs and HCFCs), ammonia, chlorine, mercury and mercury-containing devices, PCBs, 1,1,1-Trichloroethane, etc.

DB

DESIGN BASIS REVIEWED BY: (NAME/ SIGN/ DATE) _________________________________




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DESIGN ENGINEERING REVIEWED BY: (NAME/ SIGN/ DATE) _________________________________

2.0 OPERATING PROCEDURES, OPERABILITY, PROCESS SAFETY (Responsible Group(s) for Consultation: Operations)

Y N NA STG

2.1 COOLING DUTY - Will change increase the cooling duty on any particular coolers? Is there any exceeding of loadings here?

DB

2.2 PUMPING CAPACITY - Will change increase the requirement for cooling water pump capacity? Is there any exceeding of loadings here?

DB

2.3 CHEMICAL FEED - Will change affect the water treatment equipment including side stream filters or chemical feed systems?

DB

2.4 CHEMICAL TREATMENT PROGRAM - Will change affect water treatment chemistry program? DB2.5 UPSTREAM OR DOWNSTREAM PROCESSES - Will any upstream or downstream processes or

equipment be affected by changes in pressure, temperature, fluid compositions and flow rate?DB

2.6.1 PRODUCT QUALITY - Do the modifications jeopardize product integrity? DB2.6.2 Is product quality changed in any way as to affect any special customers or customer contractual

requirements?DB

2.7 PRODUCTIVITY OR EFFICIENCY - Do you forsee that the modifications will adversely affect productivity or efficiency?

DB

2.8 CRITICAL SAFETY SYSTEMS - Do the modifications change any critical safety shutdown interlock systems?

DB

2.9 INCOMPATIBLE FLUIDS - Are any materials being used potentially incompatible with process fluids or inconsistent with Engineering Standards?

DB

2.10 TOXIC OR FLAMMABLE GAS - Will this change result in any possibility of introducing TOXIC or flammable gas into machinery or equipment that was previously on air or inert service?

DB

2.11.1 PROCESS HAZARDS - Will the new process changes introduce any of the following hazards: Over pressurization due to boiling of trapped saturated liquids?

DB

2.11.2 Any other new over pressurization possibilities; e.g., (1) high pressure source added, (2) increase in valve size between high- and low-pressure systems, (3) new pump or compressor or change of capacity.

DB

2.11.3 Introduce or alter any potential cause of over or under pressurizing (or lowering or raising temperature) in the system?

DB

2.11.4 Introducing air or oxygen into flammable gases? DB2.11.5 Introducing flammable into air? DB2.11.6 Introducing flammable into an inert header? DB2.11.7 Introduce a risk of creating a vacuum in the system or part of it? DB2.11.8 In any way affect equipment already installed for the purpose of preventing or minimizing over or under

pressure?DB

2.11.9 Alter the chemical composition or the physical properties of the process material? DB2.11.10 Affect the reaction stability or controllability of the process? DB2.11.11 Affect any existing trip or alarm system or require additional trip or alarm protection? DB2.11.12 If so, comment on the hazards and the corrective actions required to prevent control the hazard? DB2.12 MAINTAINABILITY – Do the modifications design incorporate positive isolation means (such as double

block & bleed, flanges for inserting spectacle blinds, spools etc) to ensure safety when isolating equipment for performing maintenance work?

DB

2.13 OPERABILITY – Are there valves or means for depressurization, defrosting, thermal relief, draining, releasing of vapor lock etc? All details, such as the addition of check valves, bleed valves for depressurization, defrost, purge points or drain valves for dead-legs, sampling points , pressure guages , regulators, insulation, etc., have been reviewed and are included in the submitted marked-up PID? Operability studies must be done before approving it for construction.

DB

2.14 NEW RELIEF DEVICES - Are new relief devices required? It is not acceptable to use a lock-open valve to eliminate the need for a relief device. In most cases, safety valves or other safety devices will have to be downstream of check valves.

DB

2.15.1 PROCEDURES – Directly alter the operating procedure of existing system? DB2.15.2 Affect drastically existing operating & maintenance or quality procedures? DB2.15.3 Need to prepare procedure before modification goes live? DB2.16 TRAINING NEEDS - Is it necessary to spell in the Scope of Work for contractor to include Vendor

training for specialised & expensive equipments such as analysers, flow computers etc?DB

2.17 COOLING WATER BALANCE - Will change affect the cooling water balance within the facility? DB2.18 LOAD ON THE COOLING TOWER / CHILLER - Will change increase the loading excessively on the

cooling tower or cooling capacity of heat exchangers or chiller?DB




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2.19 PRECLEANING – Will change require pre-cleaning? Will this create environmental issues? DB

2.20 Boiler Systems Y N NA STG

2.20.1 EXISTING STEAM, CONDENSATE, OR BFW feed - Will change affect the existing steam, condensate, or BFW water load?

DB

2.20.2 CHEMICAL CONTROL – Will change require special chemical control, i.e., anti-corrosion chemicals, amine addition?

DB

2.20.3 CONTAMINANTS – Will change add any contaminants to the boiler system? DB2.20.4 STEAM PURITY – Will change affect steam purity due to carryover, desuperheating or modified steam

drum operation? DB

2.20.5 PROCESS CONTROL – Will change require special process control, i.e., de-superheating? DB2.20.6 WATER OR STEAM ANALYZERS – Will change affect existing steam or water analyzers? Will change

equire additional analyzers? DB

2.20.7 SYSTEM OPERATING PRESSURE – Will change affect system operating pressure? DB2.20.8 CHEMICAL FEED SYSTEMS – Will change affect chemical feed systems? DB2.20.9 MAKEUP WATER PRETREATMENT – Will change affect makeup water pretreatment system? DB2.20.10 PRECLEANING – Will change require pre-cleaning? Will this create environmental issues? DB2.20.11 BASIC ENGINEERING PRACTICES FOR SAFETY – Has a review been performed of the Basic

Engineering Practices for Safety to determine if specific hazards are being introduced or created by the change and has the design included all the necessary countermeasures?

DB

2.20.12 If specific hazards are being introduced or created by the change and has the design included all the necessary countermeasures?

DB

2.21 Is there any Site Acceptance Test that should be carried out before allowing commissioning to proceed? The Project Chart or Gnatt Chart should be reviewed by the Operations to ensure that they are carried out ahead before commissioning can be allowed to takes place.

DB


DESIGN ENGINEERING REVIEWED BY: (NAME/ SIGN/ DATE) _________________________

3.0 MACHINERY AND MECHANICAL EQUIPMENT, PIPING, VESSELS AND MATERIALS OF CONSTRUCTION (Responsible Group(s) for Consultation: Mechanical Engineering)

Y N NA STG

3.1 SAFETY FEATURES – Will this change alter safety features or safety requirements of affected machinery and equipment?

DB

3.2 MIS-OPERATION – Will there be an affect on the machinery or mechanical equipment due to mis-operation or failure of the intended modification?

DB

3.3 AUXILIARY SYSTEMS – Will this change affect any of the auxiliary systems for the affected machinery or equipment: lube system, seal gas system, vent system, cooling water system, etc.?

DB

3.4 RELIABILITY – Will this change reduce the reliability of affected machinery or equipment? DB3.5 SPARES – Will this change involve replacement of parts with modified or non-OEM parts? Is there a

risk here? DB

3.6 DESIGN CONDITIONS 3.6.1 Will new modifications cause the process conditions to exceed the design maximum conditions –

pressures, temperatures and flows? DB

3.6.2 Are there any cyclic pressure/temperature conditions or vibrations? Cyclic pressure/temp changes may cause material fatigue and failure.

DB

3.6.3 Will the design conditions be changed? DB3.7 CODES/SPECIFICATIONS – What design/fabrication codes and specs apply? Are they specified

upfront in the new equipment design specifications? DE

3.8 MATERIALS - Are all the materials compatible with process fluid within design envelope? For oxygen service, check velocity and compatibility against Eng. Stds. And O2 Compatibility Manual. For process

fluid which is corrosive, special gaskets and suitable piping material need to be used.

DE

3.9.1 'CODED' VESSEL OR PIPEWORK - Is an authorized or independent inspection authority required? DE3.9.2 What is scope of their involvement in both design and fabrication? DNV or ABS engineering review

required?DE

3.10 VESSEL/HEAT EXCHANGER/TANK DESIGN – Y N NA STG

3.10.1 Is the vessel or equipment being modified or design conditions change? DB




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3.10.2 Do we require a PE to re-certify approve and certified on engineering calculations for vessel design? Is the vessel or equipment being modified or design conditions change?

DB

3.11 PIPEWORK DESIGN – Y N NA STG

3.11.1 Is stress analysis required for new pipework or a change in pipework configuration? DE3.11.2 Are isometric or General Arrangement drawings required? DE3.12 PIPEWORK LAYOUT – Is the piping layout reviewed and endorsed by the Operations Representative

whether it causes any tripping hazard, or obstruct the operations & maintenance activities in the immediate vicinity?

DE

3.13 PIPEWORK COMPONENTS - Do all components satisfy appropriate piping specs? Confirm any 'line items' not included in piping spec (e.g., bellows or flexible hoses) are suitable for design conditions and satisfy engineering codes requirements?

DE

3.14 PIPEWORK SUPPORT - Are the supports and foundations adequate? DE3.15 MATERIAL CERTIFICATION - Are material certificates required? Is full traceability of material

required? Do we require positive material identification (PMI)?DE

3.16.1 WELDING - Does the contractor have suitable weld procedure specifications which satisfy our requirements and qualified to code requirements?

DE

3.16.2 Is welder qualified and certified by local authorities? Do welds require post weld heat treatment for process reasons?

DE

3.17 NDT - What non-destructive testing is required to satisfy SCU design specs and code requirements? DE3.18 FABRICATION/TOLERANCES - Are there any special and/ or additional tolerance or fabrication

requirements?DE

3.19 PRESSURE TESTING - Do we have a written procedure to identify piping sections and steps of sectionalized t esting? Hydraulic tests are significantly safer than pneumatic tests. How safe is it to pressure test 'old' equipment for personnel and equipment? What impact do the safety distances have?

DE

3.20 SUPERVISION - Who is the designated to monitor & supervise main contractor’s activities? What access is required - scaffolding, lighting power, proper lifting equipments, properly selected crane? Are they adequately provided for by main contractor? The O&M staff should be empowered to monitor and stop work if they are being compromised so as to affect safety.

DE

3.21 CLEANLINESS - The standard of cleanliness of new fabricated equipment should be communicated upfront so that when carrying out pre-commissioning activities to clean the vessel – the contractor will be contractually obliged to provide the workers and cleaning equipments. For example, air blowing , pigging, vacuum drying, inerting with N2 etc

DE

3.22 PAINTING - Is painting required? What SCU previous project spec applies? Is vendor standard acceptable?

DE

3.33.1 INSULATION - The insulation cladding must not conceal equipments & items such as check valves and strainers. Where this may be impractical (due to heat leak, etc.), the insulations shall have obvious markings externally indicating the device. Usually, this requirements need to be made known upfront to insulation contractor to prevent rework and delays. Is this informed to contractor?

DE

3.33.2 Is insulation required at the new modifications? 3.34 PROTECTIVE DEVICES -

Y N NA STG

3.34.1 Addition of bypasses and regulators (or other pressure reducing devices) will require special attention. Existing safety devices may not handle increased flows or pressures if the pressure reducing device fails or a manual bypass is opened (relief device must be designed for full open in both cases). Do we have documentation/datasheets on relief valve; rupture discs, hardwired safety tripping logic, over pressure protection system?

DB

3.34.2 Does the modification have an impact on the protective device or trip system, which requires further calculations review by PE? New upgraded over pressure protection system must be site tested and witnessed by O&M staff during FAT and SAT.

DB

3.35 DOCUMENTATION - What documentation and/or certification is required to satisfy legislation and SCU requirements on records traceability of new equipment performance results. Who needs the documentation? Do we require the Vendor to provide test certificates or reports for new equipments? Do we expect performance & efficiency test results and calculations reports? Report requirements should be included in Deliverables or Scope of Work to Contractor so that they can plan & budget for it. Is the contractor expected to perform Site Acceptance Test with proper reports for equipment?

DE

3.36 MAINTENANCE ACCESS – Y N NA STG

3.36.1 Will this modification impair access to or maintenance of the equipment? DE3.36.2 Has the ability to safely isolate the machinery or equipment been affected? DE3.36.3 NEW EQUIPMENT TAG NUMBERS - Will this change require new equipment tag numbers? New Tag

numbers must be compatible with existing nomenclature (KKS code) used in SAP.DB




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3.36.4 COMMISSIONING STRAINERS - Should temporary commissioning cone strainers be added to protect machinery from debris from piping changes upstream? The startup strainers are removed immediately after the pre-commissioning cleaning & flushing activities or sometimes many months after plant operations.

DE



4.0 CONTROL SYSTEM (Responsible Group(s) for Consultation: Instrumentation Engineering) Y N NA STG

4.1 P&ID CHANGE NOTE OR FLOWSHEET CHANGE -

4.1.1 Have tag numbers been assigned to any additional instruments? Make sure the Nomenclature used follows the existing standards and guidelines.

DE

4.1.2 Have the relevant Control System Safety Integrity Levels been identified (Level 1 - regulatory control, Level 2 - major capital equipment protection, Level 3 - safety protection)?

DE

4.1.3 Has the control platform been identified (i.e., DCS, local panel, trip panel)? DB4.1.4 Has the failure action mode of control valve been identified? DE4.1.5 Have voting systems been defined (i.e., 1 out of 2, 2 out of 2, etc.)? DE4.1.6 Has final drive, solenoid, etc., been defined as energize or de-energize to trip? DE4.2.1 INSTRUMENTATION PROTECTIONS - Is the location of the new instrument s or analyser prone to

induced current from lightning nearby? DE

4.2.2 Is proper instrument earthing provided? DE4.2.3 Any need for surge protectors if instrument analyser is very expensive? DE4.3 RELIABILITY ISSUES - Y N NA STG

4.3.1 Have common cause failure mechanisms been considered (i.e., component or power supply failure may cause failure of both plant and backup system)? Are there any single point failures within the new modifications which could jeopardize plant availability? Do we want to introduce redundancy on the design?

DB

4.3.2 Do we need to carry out Failure Mode Effect Analysis (FMEA) to thoroughly assess and identify further shortcomings?

DE

4.3.3 Have requirements for backup power supply been considered (i.e., UPS, on-site diesel generator, backup instrument air supply)?

DB

4.4 INSTRUMENT DRAWINGS - Has a list of instrument drawings which required updating prepared? This list is for tracking and monitoring changes completed. These are the drawings which require updating if MOC is implemented. It includes CAD drawings, control panel schematics, interconnection drawings, instrument list summary, hazardous area classifications location drawings, loop diagrams)

DE

4.5.1 FLAMMABLE GAS HAZARDOUS AREAS - Is a hazardous area created or extended due to addition of equipment?

DE

4.5.2 Is additional equipment located in an existing hazardous area? DE4.5.3 Introduce or alter the location of potential leaks of flammable material? DE

STANDARD INSTRUMENTATION -4.6 Is the proposed instrumentation sourced from an approved vendor for the duty to be used? DE4.7 Is the proposed instrumentation having locally available spares and service support at reasonable cost? DE4.8 Is there any new flow sensor, analyser instrumentation or custody transfer meters; that designed

specifications must meet customer’s requirement on accuracy tolerance? If yes, verify the contractual needs on agreed tolerance if available.

DE

4.9 DOCUMENTATION & VALIDATIONS- What documentation and/or certification are required to satisfy legislation and SCU requirements on records traceability of new equipment performance results? Who needs the documentation? Examples are requirement for Contractor to generate high quality detailed loop validations reports, as built termination drawings, Calibration reports, performance & efficiency test results and calculations reports, calibration certificates for custody transfer meters and pressure, temp sensors. Is Contractor expected to perform Site Acceptance Test for new equipments with proper reports? Report requirements should be included in Scope of Work to Contractor so that they can plan & budget for it. If loop validation by Maintenance people is required etc, we should specify in Scope of Work for contractor to provide the budget, necessary tools and manpower etc. Is this required?

DE



5.0 ELECTRICAL (Responsible Group(s) for Consultation: Electrical Engineering)Y N NA STG




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5.1.1 NEW / UPGRADING EQUIPMENT - Introduce new or alter existing electrical equipment? DB5.1.2 What is the rating of existing equipment and the proposed upgraded rating of existing equipment? DE5.1.3 Any chances of overloading or tripping the upstream common breaker? DE5.1.4 Will the change require soft starter or Variable Frequency Drive (VFD) or will the equipment

generates undesirable harmonics?DE

5.1.5 What additional control features are desired for new equipment (start/stop, relays, protective devices, etc.)?

DE

5.2 Are any additional interlocks or trip relays required? DE5.3 LIGHTING - Is additional lighting or emergency lighting required? Cost to provide such additional

facilities should be bundled upfront. DE

5.4 Is a hard wired emergency stop button for equipment required? DE5.5 Is equipment suitable for the hazardous area classification? DE5.6 Are there any changes to the Area Classification? If yes, does explosion proof equipment & devices

required? DE



Further comments of critical concerns based on checklist above. What problem has been created which affects plant or personnel safety or health or the environment and what action is recommended to minimise or contain it; so that implementation can still proceed?

APPENDIX 5PUNCHLISTING GUIDELINES

(All CAT AN items must be cleared before commissioning is allowed)




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1.0 LINE CHECK ACCORDING TO EFD OR PID

1.1 Check for wrong connecting point 1.2 Check for correct location & directions of instruments and piping components (e.g. Check valve, strainer,

sight-glass, etc.)

1.3 Spectacle blinds are correctly located.

1.4 Vent valves and drain valves are correctly located

1.5 Check for correct level of liquid seal

1.6 Check for correct sloping and piping.

1.7 Ensure that correct material and pressure rating are used in piping and it’s auxiliary for high temp, high pressure and low temp service.

1.8 The section of pipeline between two valves shall be provided with either a drain valve or pressure relief valve.

1.9 Ensure complete draining is possible for piping especially at low points.

1.10 Correct direction of globe valve, non-return V/V, butterfly valve, actuators, flowmeters (Orifice type) etc.

2.0 ACCESSIBILITY

2.1 Valves shall be positioned in such a way that stems at full-opening will not cause any obstruction.

2.2 Valve handwheels are easily accessible.

2.3 Strainers are easily removed for cleaning, no obstructions for opening.

2.4 Platforms are suitably located.

2.5 Ladders and handrails are properly mounted from safety point of view.

2.6 Instruments are easily accessible.

2.7 Piping and instrument stanchions will not obstruct platforms or walkways.

2.8 All instruments, e.g LG, PG, TG are easily visible.

3.0 GOOD MAINTENANCE

3.1 Safety valves can be easily serviced.

3.2 Instruments can be easily serviced.

3.3 Bonnets of large-diameter valves are easily serviced.

3.4 Gaskets can be easily replaced for valves and fittings that need to be serviced regularly.

3.5 Valve keys / F- keys provided provided for big valve operation.

4.0 PIPING WORK

4.1 Piping is properly supported.

4.2 Fixed points of piping subject to thermal expansion are correctly located...

4.3 Spring supports are correctly located.




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4.4 Expansion joints are correctly located.

4.5 Discharge piping of safety valves is properly supported.

4.6 Piping shall be properly supported to prevent excessive sagging, vibration and strain on connected equipment.

4.7 Ensure that no gas accumulation at pump suction piping.

4.8 Piping should not obstruct the removal of equipment

4.9 Piping installed with small-diameter nozzle is properly supported.

4.10 Outlets of safety valves or vents (for non H/C service) etc shall be led to a safe location.

4.11 Valve gland leakage shall not cause serious damage to equipment or piping.

4.12 Enough clearance between insulation material of equipment of piping and associated components (estimate).4.13 Drain valves of steam lines are properly located.

4.14 No obstruction around fire-hydrant area.

4.15 Check for correct direction of CV, orifice and instrument

4.16 Check for correct direction of check valves, SG, steam traps and other piping components.

4.17 Rotameter and float-type level transmitters are installed vertically.

4.18 Special materials, internal / external coatings for piping and associated components are correctly used.

4.19 Use right material for gaskets.

4.20 Check for correct position of gasket.

4.21 Flange-bolts shall have the correct length.

4.22 Flanges are completely bolted.

4.23 Flanges are properly aligned.

4.24 Open end of drain nozzle is properly threaded.

4.25 Ensure that no defects at welded section of piping.

4.26 Ensure that no liquid seal at tile horizontal section of vapour equalisation lines.

4.27 Remove unnecessary blind plates after testing of individual equipment.

4.28 Check that piping with reducer can be completely drained.

4.29 Ensure no contact between piping and equipment

4.30 Check for correct tag-no for instruments and piping components.

4.31 Check for labelling of cables, Junction box & Patch panel labelling.

4.32 Check for availability of as build drawings given inside the junction box.

5.0 OTHERS




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5.1 Check that paint work is complete and correct paint spec or galvanising thickness used.

5.2 Clear debris on the platforms.

5.3 Check that lighting is properly located with enough lumination.

5.4 Clear debris in the pit

5.5 Check for welded-ring on structure floor where piping passes through it.

5.6 Ensure Fire detection system properly tied in to (pilot or hydraulic)

5.7 No tripping hazards

5.8 All emergency push buttons must have plastic protective cover

5.9 All falls hazard must not be present

5.10 Fire extinguishers must be covered!

5.11 All equipment’s must have easily reach for maintenance

5.12 Adequate means taken to discharge static charges.

5.13 Adequate warning signages must be provided.

5.14 Power cables and instrument control cables should not lie in same cable tray or crosses.

APPENDIX 6




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PART 2.0 MOC CHECKLIST (PRE-COMMISSIONING CHECKLIST) (To Be Driven by Facility’s Operation SV)

Y N NA1 Modification completed and walk down completed to check against as built PID drawing? (Opns to

check) 2 Punchlisting by multi-disciplines completed? (Project to organise) 3 Punchlist done according to Punchlist Guidleines in the below sections?4 Is the Pre-Energization Checklist completed satisfactory? (Check with electrical)5 Is the Run-In or Flushing Checklist in the below section completed? (Project to assist Opns)6 All CAT A punchlist cleared? (Opn to verify with Project)7 All actions called for in detailed Safety, Health and Environment Assessment (MOC Form, Part 1),

Including hazard study actions is completed. (Opn verify with Projects& HSE)8 COMMSSIONING PROCEDURES - If the new equipment has special commissioning instructions, or

the modification involves process design changes, trip interlock logic change and operating procedure changes - then a new commissioning procedure is mandatorily required to be reviewed and approved by Operation Manager before proceeding for safety sake. Is this required? (Vendor provide procedure, Opn endorse and improve it)

Y N NA9 All PTW’s signed off? (Opns) 10 Is there evidence that all new/modified equipment items were tested as per design requirements?

Was there FAT or SAT records to proof that they perform satisfactorily to design specifications? (Check with Mech/I&C. Any FAT or SAT records?)

11 New equipment’s Data sheet verified against design specifications? Any non-compliance but special waivers should be identified here?

13 Is the newly fabricated piping, equipments, vessels – material used fabricated according to relevant specifications? (Check with QA/QC)

14 Is Certificate of Mechanical Compliance (issued by PE) required and received? (Check with QA/QC)

15 NDT & Hydro test report satisfactory? (Check with QA/QC). 16 Certificate of mechanical completion issued to contractor? (Projects)17 All newly installed safety protective devices site tested and witnessed? For example, online gas

detectors, smoke detectors, flame detectors, over pressure protection system (OPPS), pressure switches (PSHH); temperature switches (TSHH) etc. Documentary proof should be available for such tests. (Checked with I/C Loop Test records)

18 MOM registration documentation received for registered pressure vessel? (Projects) 19 All new/modified instrument loops checked, tested and labelled? (check with I/C instrument list) 20 All relevant trips and alarms tested and setting verified? (safety interlocks, BMS (Burner

Management System) , hard wired ESD system ) 21 Operating teams trained in new operating philosophy?22 Other relevant staff informed/trained? 23 Relevant third parties notified? (E.g. neighbouring plants/ facilities /companies)?24 All warning/information notices and labels fitted? (Visual check during 100% walkdown)25 All piping checked for support, freedom of movement, etc.?26 All spring-supports released? (Check with mechanical)27 All non-essential scaffolding removed? (Visual check in the field)28 Access available to all equipment (e.g. instruments, valves) (Check with I/C)29 Full check against master design drawings (e.g. P&ID’s) complete?30 Instrument visual checks complete? Opns check all instruments are commissioned.31 Instrument “first isolations” open? 32 Any special instrument commissioning procedures required? (Check with I/C) 33 Trip systems live or enabled? (fuses/bypasses/jumpers removed) (Check with Electrical)34 Are the safety interlocks validated on site?35 All essential insulation and fire protection fitted? 36 Process valves correctly lined up for commissioning? Opns to check37 Drain and vent valves shut plugs & end caps fitted? (Visual check during 100% walkdown)

Y N NA38 Plant tidy? All hazards and debris removed? (Visual check during 100% walkdown)39 All pre-commissioning work completed? (E.g. line blowing/ flushing, Inspection, leak testing, purging,

inerting, vacuum drying etc).40 Emergency procedures to incorporate the modification made available? Opns to prepare 41 Safety Signages for the new hazard introduced displayed? (Visual check during 100% walkdown)42 Moving parts adequately guarded: belts, gears, rolls, etc.? (Visual check during 100% walkdown)




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43 Sharp edges removed or guarded? (Visual check during 100% walkdown)44 Bumping and tripping hazards adequately guarded? (Visual check during 100% walkdown)45 Adequate lighting and ventilation during commissioning? (Visual check during 100% walkdown)46 Provision for locking out and checking effectiveness of lockout? 47 Adequate drains for liquid at low points of system? (Visual check during 100% walkdown)48 Extra safety equipt. Required, (face shields, E. shower, Fire extinguisher)?49 Is the fire protection system incorporated and adequate? (Site acceptance test )50 For new chemicals, is documentation complete (poison permit)? 51 Are the correct equipment identification labels provided? (Visual check during 100% walkdown)52 Is bolting per design specs? (Check with Mech or QAQC)53 Are gaskets used according to ratings or per design spec? QAQC & Visual check during 100% walkdown.54 Has metallurgy of critical equipment been confirmed ?(QAQC) 55 Has project piping P-code been followed? (check with QA/QC)

Y N NA56 Have specified valves (removed for servicing) been installed? (Maint)57 Is equipment flush and drain points adequate in new design? (Opns)58 Are all piping supports in place and are they adequate? (Mech)59 Has all rotating equipment been aligned to specs? (Mech) 60 Has specified lubrication been installed in all rotating equipment?61 Is required rodent and insect intrusion protections provided? (Visual check during 100% walkdown)62 Is accessibility adequate for routine operations and maintenance? (Visual check during 100%

walkdown)

PART 2.1 MOC CHECKLIST - (PRE-ENERGIZATION CHECKLIST - Opns to verify with Electrical Maintenance)

Y N NA1 Provision for locking out and checking effectiveness of lockout? 2 Are the required emergency switches provided? 3 Electrical systems labeled and fused-up? 4 Has fire protection adequacy been reviewed? 5 Is there adequate means of exits or escape routes?6 Wiring complies with National standards? 7 Is all equipment appropriate for the electrical classification of area? 8 Does equipment operate safely within the specified range (s)? 9 In the event of failure of equipment, has safety of others in area been considered? 10 Has electrical phasing been checked?11 Are all wires safely terminated and continuity checks performed?12 Are all correct breakers, fuses and overload heaters installed?13 Have all grounded clusters been removed?14 Have equipment and circuits above 120 VAC been megger tested? 15 Is all equipment properly grounded? 16 Has each individual grounding system been checked?17 Is the equipment, building lightning grid adequate?18 Is there rubber mat provided for switch gear area?19 Have you verified that each piece of electrical equipment has a fault return path back to secondary

side of its appropriate sub-station transformer centre tap?20 Is the electrical resistance of the fault return path within tolerance?21 Is min. 6oz. or equivalent flash protection suit & switching PPE available in sub-stn. ? 22 Are the required warning signs provided ?23 Are the equipment identification labels provided?24 Are disconnects, starter switches and loads properly and consistently labelled?25 Are relevant electrical codes and practices (NEC, NFPA, S’pore CP’s) adhered?26 Check whether fuses & trip relay & MCB are correctly rated for electrical device? (Check with

electrical)27 Electrical/Instrument equipment in hazardous areas registered and inspected?

PART 2.2 MOC CHECKLISTS




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(PRE-RUN IN OR FLUSHING CHECKLIST -Commissioning Supervisor to find out)

PRE-RUN IN OR FLUSHING PROCEDURES – An operation approved procedures must be prepared to perform equipment is flushing to clean pipeworks of welding slags & construction debris, or steam blowed, or pigged (for ball valves). After blowing or cleaning, some valve bodies may need to be opened immediately to remove collected debris from the valve seats. Otherwise, the valves seats will be damaged and become passing. The pre-commissioning procedures must cover these procedures & identify the stages of sectionalized cleaning of the new pipe work modification. Is this required and available? Y / N /A

IMPORTANT INFORMATIONS TO KNOW BEFORE RUN-IN1. OPERATING CONDITIONS FOR RUN-IN OR FLUSHING

Vacuum (Bara) (mnlHG) Presssure (barg) Temperature (deg C)

2 . TEMPERATURE CONSIDERATIONS

What is the maximum allowable temperature (deg C)?

Heat source: Steam, electrical, hot water, direct fired? Are over-temperature controls provided? Yes No

Personnel protection provided for hot surfaces: Yes No > 6O deg.C?

3. HAZARDS OF MATERIALS CONTAINED IN THE SYSTEM

o Flammable liquids? Y / N /NA

o Toxic? Y / N /NA

o Corrosive liquid? Y / N /NA

o Skin Irritant? Y / N /NA

o Respiratory irritant? Y / N /NA

o Unstable reaction mixture? Y / N /NA

o Explosive gas mixture? Y / N /NA

o Oxygen deficient atmosphere? Y / N /NA

4. EMERGENCY PRESSURE RELIEF

o Is a pressure relief v/v provided? Y / N /NA

o Have the relief valve calculations been documented? Y / N /NA

o Has the relief valve been checked and set in the shop? Y / N /NA

5 EMERGENCY PRESSURE VENTING




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o Does the relief valve vent to an acceptable location? Y / N /NA

o Is information sufficient on process and materials to ensure an understanding of hazards involved?

Y / N /NA o Extra safety equipment required, such as face shields? Y / N /NA

o Does all interlock wiring comply with appropriate classification? Y / N /NA

o Have any interlocks been bypassed for run-in or flushing? Y / N /NA

o If so, has the proper documentation been filled out (interlock By-pass form)? Y / N /NA

NAMES OF PERSONS IN O & M WHO ARE INVOLVED IN Part 2.0, 2.1, 2.2 CHECKLISTS

NAMES DEPARTMENT SIGNATURE

OPERATIONS

QA/QC

INSTRUMENTATIONS & CONTROL

MECHANICAL

ELECTRICAL

HSE




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APPENDIX 7

PART 3.0 MOC CHECKLIST

CHECKLIST FOR POST IMPLEMENTATION VERIFICATION & DOCUMENTATION

OperationsPERSON IN CHARGE OF CHECKLIST: ____________________________

3.1 OPERATIONS Y N NA

3.1.1 Have the Modifications been implemented as approved? Note that if the MOC has been implemented in a manner not consistent with the “Issue for construction” design, the MOC shall be revised and resubmitted for review and approval.

3.1.2 Is the modification‘s intent fully satisfied or is there a need for fine tuning or further changes?3.1.3 Should this modification be considered for future or similar plants within the SCU units?3.1.4 After monitoring the modifications’ live performance, any unexpected negative impacts on reliability,

availability, risks, efficiency etc? If yes, please give recommendations on counter-measures. 3.1.5 Have the affected personnel (operators, maintenance and in-house contractors) been informed of and

trained in this change? 3.2 HSE Y N NA3.2.1 All safety signages for new mod put up? 3.2.2 Noise level measurement need to be conducted on new modifications?3.2.3 Have all the recommendations in the risk assessment been executed?3.2.4 Have all the recommendations in the safety review been executed?3.2.5 Are the Emergency Procedures identified during the Design review prepared?3.3 MATERIAL AND SYSTEM Y N NA3.3.1 Is the inventory control database (SAP) updated on the changes of spares type & quantity affected by

the modifications?3.4 MAINTENANCE3.4.1 Is there a requirement for a new third party maintenance program for specialized & expensive

equipment? Eg. Compressor, analysers etc 3.4.2 Is there a need to remove old equipment records and obsolete PM tasks? 3.4.3 Is the Plant Preventive Maintenance program or SAP updated to include the new equipment

introduced?3.4.4 Are all critical spares for the new equipment identified, purchased and included in inventory control

management database? 3.5

DOCUMENTATION UPDATE REMINDERS Y N NA

3.5.1 Is the plant Master as-built P&ID drawings updated to include the new modifications?3.5.2 Are the plant as-build onsite electrical drawings, termination diagrams updated to include the new

modifications?3.5.3 Is the DCS configuration drawings, loop drawings, instruments termination diagrams updated to

include the new modifications?3.5.4 Are there any pressure vessel modifications (steam and air service), is there a master records register

of all pressure vessels which requires annual inspections need to be updated?3.5.5 Is the operation procedure for the equipments or process amended to incorporate the changes or

modifications?3.5.6 Did the Vendor submit all data sheet & equipment specs of new equipments to the O&M staff? 3.5.7 If there is a new relief valve, is it incorporated into the Master PSV listings? Master PSV listing is for

tracking bench test or calibration due dates, locations, settings etc.3.5.8 Is the approved calculation for the new Pressure relief valve sizing given and filed by appropriate

personnels? 3.5.9 Are there any previous Hazop studies or QRA report on the equipment prior to its modification? If there

is, is there an amendment update sheet to attach within the QRA report for the new modification? 3.6 EQUIPMENT DESIGN BASIS (updated, documented and filled) Y N NA3.6.1 M&E list 3.6.2 Blue print file 3.6.3 P &I drawing 3.6.4 Electrical drawing 3.6.5 Equipment arrangement drawing 3.6.6 Equipment calculations 3.6.7 Equipment specifications




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3.6.8 Relief device calculations 3.6.9 Interlock classification 3.6.10 Instrument calibrations 3.6.11 Logic drawing 3.6.12 Vent system design basis 3.6.14 Isometrics3.6.15 DCS 3.6.16 DCS backup disk 3.6.17 Trends in DCS

3.7 PROCEDURES UPDATING Y N NA3.7.1 OPERATING3.7.1.1 Initial start-up 3.7.1.2 Normal start-up / shutdown3.7.1.3 Emergency shutdown 3.7.1.4 Emergency operations 3.7.1.5 Standard operating conditions

3.7.2 MAINTENANCE Y N NA3.7.2.1 Rotating equipment 3.7.2.2 Safety interlock function check3.7.2.3 Relief device testing3.7.2.4 Electrical 3.7.2.5 Instrument3.7.2.6 Corrosion monitoring 3.7.2.7 Pressure vessel inspection3.7.2.8 Expansion joint inspection3.7.2.9 Fire protection equipment tests 3.7.2.10 Overspeed and / or overload device tests

3.7.3 LAB Y N NA3.7.3.1 Sampling Methods3.7.3.2 Lab records 3.7.3.3 Equipment Training records3.7.3.4 Process overview3.7.3.6 Operating procedures

3.8 EQUIPMENT INTEGRITY RECORDS DOCUMENT ( updated by Maintenance) Y N NA3.8.1 Hydrotest equipment 3.8.2 Leak checks 3.8.3 Instruments calibrated 3.8.4 Loop alarm checks3.8.5 Loop interlock checks 3.8.6 Electrical systems check 3.8.7 Electrical continuity check 3.8.8 Equipment rotation check 3.8.9 DCS configuration 3.8.10 Safety interlocks tested 3.8.11 Fuse and overloads3.8.12 Circuit breakers tested 3.8.13 Relief devices tested 3.8.14 3-way valve positioning verified 3.8.15 Pressure vessels inspected 3.8.16 Emergency shutdown devices 3.8.17 Electrical grounding/bonding3.8.18 Protective relays coordination 3.8.19 Motorised Valves tested




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3.8.20 Lifting devices load tested 3.8.21 Electrical functions check 3.8.22 Torquing / bolt tensioning

3.9 QUALITY ASSURANCE RECORDS (Updated by QA/QC) Y N NA3.9.1 Equipment installed per design 3.9.2 Materials of construction per design 3.9.3 Equipment pressure and temperature 3.9.4 Ratings as per design 3.9.5 Gaskets installed as per design




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APPENDIX 8

MASTER REGISTER OF MOC

S/NO MOC NO. FACILITY DESCRIPTION OF CHANGES DATE SUBMITTED STATUS MOC LEADER

management of change

Documents

mgr hod hod hod

modifications changes

changes modifications

new facilities

plant equipment

process plant changes

plant facilities equipment

document title