Refinery Process Catalyst Post-Start-Up Review

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Process Safety Guide:
GBHE-PSG-HST-070
Study 6: Project Close-out /Post
Start-up Review
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Process Safety Guide: Study 6: Project Close-out /Post Start-up
Review
CONTENTS
6.0 PURPOSE
6.0.1 Team
6.0.2 Timing
6.0.3 Preparation
6.0.4 Documentation
HAZARD STUDY 6: APPLICATION
6.1 METHOD
6.2 REVIEW OF HAZARD STUDY 6

6.0 PURPOSE
The purpose of Hazard Study 6 is to provide an opportunity to:
(a) Check that Hazard Studies 1 to 5 has been completed, and relevant
documentation exists in the Project SSHE dossier (worksheet j);
(b) Review early operation to ensure that it is consistent with the design intent
with regard to safety, health and environmental issues, and that
assumptions defined in earlier Hazard Studies are borne out in actual
operation;
(c) Identify and record operating and maintenance difficulties, and ensure
feedback to the design engineering organization responsible for the
project.
This document should be used in conjunction with a process safety publication
such as ’HAZOP: Guide to best practice’ (available from IChemE) or ‘Guidelines
for Hazard Evaluation Procedures’ (available from CCPS).
6.0.1 Team
The study team should include:
(a) Commissioning Manager/Plant Manager;
(b) Project Manager;
(c) Hazard Study Leader/Safety Adviser, and where relevant: the Business
Engineering Manager, Plant Engineer, Process Engineer, Environmental
Specialist and Occupational Hygienist.
6.0.2 Timing
Timing is most important for the successful completion of Hazard Study 6.
Although it is important that this study is based on operating experience, a
long delay can mean that the project and commissioning teams have been
dispersed.
The study should ideally take place not earlier than 3 months and not later
than 6 months following the establishment of beneficial production.

6.0.3 Preparation
The following information required for Hazard Study 6 should be in the
SHE Dossier:
(a) Reports from Hazard Studies 1 to 5.
(b) Accidents and dangerous occurrence reports.
(c) List and details of modifications.
(d) Results of workplace monitoring (noise, vapors, dust).
(e) Environmental monitoring and incidents.
(f) Reports from safety inspections.
Appropriate members of the project and commissioning teams should be asked
to identify particular SHE-related issues which they think should be reviewed
during Hazard Study 6.
6.0.4 Documentation
A note should be added to the Project SSHE dossier (worksheet j)
confirming that Hazard Study 6 took place and summarizing any actions
identified and the responsibility for completion.

HAZARD STUDY 6: APPLICATION
The following sections 6.1 and 6.2 describe how to conduct Hazard Study 6.
6.1 METHOD
The points raised in part 1 and part 2 of the worksheet (worksheet t) should be
systematically considered.
Particular attention should be given to:
(a) Review of operating experience (versus design conception).
(b) Review of modifications, with significant hazard implications, made during
the commissioning and start-up and check that the Piping and Instrument
Diagrams (P&IDs) or Engineering Line Diagrams (ELDs), plant
documentation and operating instructions have been updated.
(c) Review of operation of the trip and alarm systems in terms of demand
rates, spurious trips, trip defeats, interlock problems, and problems with
testing.

(d) Occupational health: review results of monitoring, exposure of operators,
and frequency of leaks and spillages, are all in line with assumptions
made for the Basis for Safe Operation.
(e) Environment: review performance against consents, continuous
discharges, and abnormal discharges.
A record shall be kept in part 3 of the worksheet (worksheet t) of points raised
that require further consideration, actions identified, and responsibilities
allocated.
6.2 REVIEW OF HAZARD STUDY 6
At the completion of Hazard Study 6 the following key activities should have been
completed:
• Actions should have been assessed, reviewed and closed out.
• Possible improvements, to be considered for future similar projects,
should have been recorded.

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