GBH Enterprises, Ltd.

Process Safety Guide:

GBHE-PSG-HST-050

Study 4: Construction / Design

Verification

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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries

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 Process Safety Guide: Study 4: Construction / Design Verification

CONTENTS

4.0 PURPOSE
4.0.1 Team
4.0.2 Timing
4.0.3 Documentation

HAZARD STUDY 4: APPLICATION

4.1 METHOD
4.1.1 Installation Check
4.1.2 Implementation Check
4.1.3 Modification Check

4.2 REVIEW OF HAZARD STUDY 4

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries

Web Site: www.GBHEnterprises.com

 4.0 PURPOSE

The purpose of Hazard Study 4 is to check that the project has been constructed
as the design intended, that actions from previous Hazard Studies have been
completed and implemented in the design and installation, that detailed
implementation of the project meets regulatory and company requirements.

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).

4.0.1 Team

The Commissioning Manager is responsible for the completion of study 4

with or without the assistance of site or project resources as appropriate.

4.0.2 Timing

Hazard Study 4 should be completed prior to the introduction of process

materials, or the commencement of operations, whichever is the sooner.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries

Web Site: www.GBHEnterprises.com

 While study 4 cannot be finished until the plant is mechanically complete,
it can be started almost immediately after the completion of study 3 with
the closing out of Hazard Study Actions. Regular visits to the plant during
construction can surface concerns at a time when they can be addressed
with the least possible impact on the schedule.

4.0.3 Documentation

The Commissioning Manager should arrange for the addition of relevant

documents to the Project SSHE dossier (worksheet j). A list of outstanding
actions should be produced and added to the dossier.

HAZARD STUDY 4: APPLICATION

The following sections 4.1 and 4.2 describe how to conduct Hazard Study 4.

4.1 METHOD

This study will require many actions to be carried out by a number of people, all
coordinated by the Commissioning Manager, and will not normally involve many
formal meetings. Use of the Hazard Study 4 worksheet (worksheet r) will help the
Commissioning Manager ensure that a thorough check of the installation is
achieved.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries

Web Site: www.GBHEnterprises.com

 4.1.1 Installation Check

Check that the hardware is as the design intended and that the software
requirements are completed.

4.1.2 Implementation Check

Check that what was called for in earlier hazard studies and engineering
change orders has been implemented.

4.1.3 Modification Check

Check that modifications made during construction/commissioning have

been formally reviewed and documented.

4.2 REVIEW OF HAZARD STUDY 4

At the completion of Hazard Study 4 the following key activities should have been
completed:

• Actions from earlier hazard studies have been completed either as agreed
or that any changes to the actions are justified.

• All actions and changes have been documented.

• Changes made following Hazard Study 3 have been studied and

recorded.

• Operating instructions are available for normal operation, start-up, planned

and emergency shutdowns and, where appropriate, for maintenance and
decontamination of plant.

• Emergency procedures are available.

• A review of the arrangements for the protection of employee health,

covering the facilities provided and the arrangements for workplace
monitoring.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries

Web Site: www.GBHEnterprises.com

 • A review of the arrangements, including emergency systems, for
employee safety.

• A review of the equipment and systems provided to protect the

environment and for monitoring environmental performance.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries

Web Site: www.GBHEnterprises.com