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xxxxxxxxxxxxx Expansion Project (Additional Compressor System) PRE-START UP AUDIT. Agenda. the audit team audit objectives schedule recommendations reporting. Team members. xxxxxxxxx Facilitator xxxxxxx PDO xxxxx. HSE Performance.

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xxxxxxxxxxxxx Expansion Project (Additional Compressor System) PRE-START UP AUDIT

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Xxxxxxxxxxxxx expansion project additional compressor system pre start up audit

xxxxxxxxxxxxx Expansion Project

(Additional Compressor System)

PRE-START UP AUDIT


Agenda

Agenda

  • the audit team

  • audit objectives

  • schedule

  • recommendations

  • reporting


Team members

Team members

  • xxxxxxxxx

    Facilitator

  • xxxxxxx PDO xxxxx


Hse performance

HSE Performance

“There must always be a gap between … aspirations and performance … But a gap between policy and performance is unacceptable”

Phil Watts - Shell EP HSE Conference 22 September 1997


Standards

Standards

  • Applicable Oman laws and regulations

  • Group HSE policies and commitments

  • PDO and contractor policies, standards and procedures

  • Group and SIEP HSE guidelines such as EP95 000


Terms of reference

Terms of Reference

Scope

  • The scope is limited to those facilities, resources and controls necessary to operate the new xxxxxxxxx Expansion Facilities.

    Exclusions:

  • Corporate HSE issues not directly related to the new Facilities.


Principal positive findings

Principal Positive Findings

  • Journey management

  • The STOP initiative

  • HSE Plan updated during construction phase and signed.

  • Commissioning Plan in Place

  • WINPCS plus test ‘packs’ for construction and commissioning management

  • HEMP process for the engineering phase.


High findings

High Findings

  • No HSE Advisor is planned to be on site during commissioning.

  • No emergency preparedness plan in place for commissioning.

  • No evidence that the commissioning engineers have been assessed and meet the corporate competency standards.

  • There is no single change control register for the project including changes that have occurred in the field. The overview on changes is thus lacking.

  • Substantial completion milestone and introduction of hydrocarbons is scheduled for 9th June. This date is seen as unrealistic by many persons interviewed.


Policy and strategic objectives

Policy and Strategic Objectives

  • No significant Findings

SAQ : 2.7


Organisation responsibilities resources standards docs

Organisation,ResponsibilitiesResources, Standards & Docs.

  • Fragmented responsibility for construction activities on site. There is a lack of clarity in the roles and responsibilities from construction through to commissioning e.g.

    • There is no overall construction manager with responsibility to hand over completed construction activities to commissioning.


Organisation responsibilities resources standards docs1

Organisation, ResponsibilitiesResources, Standards & Docs.

  • No HSE Advisor is planned to be on site during commissioning.

  • No evidence that the commissioning engineers have been assessed and meet the corporate competency standards.

  • Operations were not witnessing instrument loop checks during commissioning.

  • There is no company site document controller to manage key documentation such as As-builts, vendor drawings, close-out of technical queries etc.

  • Operators have not been trained on the operations of the new compressor.

  • Only one instrument commissioning supervisor was on site as against two required in the commissioning plan.

  • Project execution plan calls for TA-2 for discipline engineers. This is in progress but not yet completed.

SAQ : 2.4


Xxxxxxxxxxxxx expansion project additional compressor system pre start up audit

HEMP

  • No structured assessment of potential hazards for some site activities e.g.

    • Safe distance for personnel during hydro testing.

    • Construction contractor supervisor had no knowledge of the safe working load of personnel basket.

  • The HSE Case has not been updated to reflect the project scope in line with the requirements of CP-117.

SAQ: 2.0


Planning procedures

Planning & Procedures

  • The overview on changes is lacking.

    • There is no single change control register for the project including changes that have occurred in the field.

    • Discipline Engineers each operate their own change control system.

    • Construction contractor does not have a change control register.

    • vendor maintaining own register of field changes.

    • Some changes proposed in field trouble reports have not been closed out.

  • No emergency preparedness plan in place for commissioning (introduction of hydrocarbons)

SAQ : 2.0


Implementation monitoring

Implementation & Monitoring

  • No incident was recorded throughout the project despite STOP cards highlighting some unsafe acts. No proactive targets were set for the project.

SAQ: 2.2


Audit

Audit

  • Audit plan in place but not fully followed.

SAQ: 2.3


Management review

Management Review

  • No Findings

4.0


Leadership commitment

Leadership & Commitment

  • Some opportunity to motivate staff in a more visible way (given the excellent HSE performance) may have been missed.

2.3


Specific issues 1

Specific issues 1

 Demonstration that HSE risks are ALARP

  • Design, installation, commissioning

  • Future operation

     HSE Case

    Close out of audits and reviews

  • HAZOP close out

     Fitness for purpose hardware

  • Constructed to design

     Effectiveness of change control


Specific issues 2

Specific issues 2

Commissioning

 Plans & Procedures

 Personnel

 Concurrent operations risks

 Procedures

 Operating, Maintenance

  • Availability and adequacy

     Emergency Preparedness Plans

     Understood and exercised


Specific issues 3

Specific issues 3

  • Operations - plans for start-up

    • Organisation

    • Responsibilities

      • PDO

    • Interfaces

      • Communications

  • Resources & services

    • Personnel

    • Spares, consumables

  • Environmental compliance


Audit opinion

AUDIT OPINION

Few  20 Findings Many  40 Findings


Audit opinion1

Audit Opinion

The overall audit opinion is

xxxxxx

Based upon there being:

xHigh Findings

xMedium Findings

xLow Findings


High and medium actions

‘High’ and ‘Medium’ Actions

  • High: People x Asset x Environment x

    Reputation x

  • Medium:People x Asset x Environment x Reputation x

    Totals: High: xx Medium: xx


Action items rated low

Action Items Rated ‘Low’

People:x

Assets: x

Environment: x

Reputation: x

Totalxx


Xxxxxxxxxxxxx expansion project additional compressor system pre start up audit

HSE MS Assessment

4

1

2

3

Leadership and Commitment

Policy & Strategic Objectives 

Organisation, Responsibilities, etc. 

HEMP

Planning & Procedures

Implementation and Monitoring

Audit

Management Review

OVERALL ASSESSMENT ATTAINMENT LEVEL 2.5


Audit recommendations

Audit Recommendations

  • PDO HSE Audits do not prescribe a schedule for the close-out of Recommendations

  • For a Pre Start-Up audit, an indication is given, in the classification of Findings of:

    • those that should be closed out prior to the introduction of hydro-carbons - classified (I)

    • those that should be closed out prior to close out of this project - classified (C)

    • those that are not directly related to project close out - classified (F)


Report principles

Report Principles

  • Report is collective view of team

    • no reference to sources

    • whole team review whole report

    • facts reported are as agreed by all the team

    • judgements are by consensus as far as practicable

    • wording agreed to as to intended meaning

    • audit leader has casting vote in case of disagreement

    • where possible, root causes identified

  • Final draft report before team disbands

    • no later changes, only minor (punctuation, grammar) editing in CO

    • final report within two weeks


Report index

Report Index

Chapters

1 Introduction

2 Executive Summary

IncludingAudit opinion and justification

3 Findings and Recommendations

Tabulated as:

Finding, Significance, Recommendation

Appendices


The end

THE END


Audit programme

Audit Programme

Sat 31/5 Opening Presentations

Doc. Review

Sun 1/6 Coastal Interviews

Mon 2/6 Visit Site - Compile notes

Tue 3/6 Return from Site

Wed 4/6 Compile Report

Sat 7/6 Draft Report/Final Presentation

Wed 11/6 Issue Final Report


Audit opinions

Audit opinions

The IAC defines 4 possible audit opinions:

  • Good

  • Fair

  • Poor (equivalent to IAG Unsatisfactory)

  • Unacceptable

    The definitions are in terms of:

  • the level of concern

  • the inference for senior management


Xxxxxxxxxxxxx expansion project additional compressor system pre start up audit

Serious: Exposes OU to a major extent in terms of achievement of corporate HSE objectives or results.

High: Though not serious, essential to be brought to Management attention. Includes medium weaknesses as repeat from previous reports.

Low: No major HSE impact at process level, correction will assure greater effectiveness/efficiency in process concerned.

Weakness Classification Matrix

A

B

C

D

E

Environ-

ment

Repu-

tation

Happens several times a year in the audited OU

Happens several times a year in the audited facility

Severity

People

Assets

Never heard of in

EP industry

Has

occurred in

EP industry

Has occurred in

the audited OU

No

injury

No

damage

No

effect

No

impact

0

123

Low

Slight

impact

Slight

injury

Slight

damage

Slight

effect

1

Minor

injury

Minor

damage

Minor

effect

Minor

impact

2

Medium

Consider-

able

impact

Major

injury

Local

damage

Localised

effect

3

High

Single

fatality

Major

damage

Major

effect

National

impact

4

Serious

Inter-

national

impact

Extensive

damage

Massive

effect

Multiple

fatalities

5

Medium: Could result in perceptible and undesirable effect on achievement of HSE objectives.


The end1

THE END


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