OBSERVATION RELATED TO THE COMMISSIONING ACTIVITY

Observation Area Subcontractor Corrective Progress

action
Expired PTW still MS block JCC All PTW shall Open
inside box sinc 510-C-002 return for
more than 4 month archive
Empty & full HCL MS block CSU Identification Open
cylinder are mixed 510 is required
Scaffolding work RFCC JCC PTW shall be
need validation for brough to
night work HSE dep for
validation
Improper support RFCC JCC Pipe shall be Open
with wood for pipe 530-R-002 reinforced by
bottom chain block
Empty HCL MS block CSU All cylinder Open
cylinder layed down shall be up and
on the floor which secured with
not comply with chain
procdure
During the support MS block DC2 A PTW is Closed
installation grating 520 mandatory for
has been removed grating
without PTW removal
Due to vibration fire MS block CPECC To be checked Open
proofing was 520-E-003 by cpecc
damaged
Empty HCL MS block CSU All cylinder Open
cylinder not secured 510 shall be
could fall on attached with
workers chain
Abnormal vibration MS Block CSU To be checked Open
of the structure and 510-TG-007 by
lighting support to 510-D-004 commissioning
team
Valve closed od MS Block CSU During Open
Safety shower & 510 acidizing
eye wash operation
safety shower
shall be open
permanently
Homemade flange MS block CSU Proper flange Open
was used during 510 must be used
acidizing operation
which may not
resist to the service
pressure 40bar HCL
Forklift windshild MS block JCC Reparation is Open
broken was 500-C-002 required
operating in MS
block
Unsafe scaffolding MS block JCC Modification Open
platform used for 520-R-001 is required
insulation work
Heat generated from MS block JCC Adequate ppe Open
reactors can easly 520-R-001 is required
make serious harm
to workers (500C)
Automatic valve has MS block DC2 All activities On going
been installed 500-D-007 shall be
without any PTW covered with
suitable PTW

Over flow of the MS block CSU To be check Open

valve pit (see
attached pict )
Missing of P&D MS Block DC2 PTW shall be Open
drawing in PTW & 510-P-009 B complete and
JSA (repair pump) clear
without any detail
Inadequate PPE MS Block JCC Informed Open
while working on 500-E- supervisor to
insulation 1A/B/C/D/E supply
exchanger adequate PPE
but no
feedback
Some PTW are not MS Block CSU&DC2 All necessary Open
complete ( missing document shall
JSA,MS& drwing ) be attached
CSU team oprator MS Block CSU Verbal Closed
are using mobile 520-k- warning was
phone inside units 002A/B given to the
operator
Hot steam has been MS Block CSU Warning Closed
generated from the 500 notification
drain point of vessel has been done
to the workers
beside
SRR2 UPS room RFCC CSU Door shall be Closed
has been left door SRR2 closed to limit
open the access for
electrical
panels
Some expired PTW MS block CSU All exoired Open
are left in the MS PTW shall be
block meeting room returned back
for archive
Steam line pipe cap MS Block CSU Cap is ongoing On going
released due to 510 Pipe to be repaired
pressure increase rack
Inorder to repair the MS Block JCC Ladder need to On going
released cap 510 Pipe be changed
,scaffolding rack
structure has been
erected with a short
ladder
Natural gas in ,using RFCC JCC Ordred to Closed
a man lift without provide bronze
Bronze tools & tools and
proper barricade in install
the bottom barication in
the bottom
Imporper storage of 510 CSU Signage & On going
DMDS which is barricade is
dangerous required
substances on site
Scaff tag is missing RFCC JCC Inspection is On going
on the scaffolding required
structure
CSU team are MS Block CSU Smoking is Open
smoking inside prohibited in
container behinde MS Block
SS23
PTW for MS Block JCC Immediately Closed
refrigeration 520-M-004 send for PTW
package has been Office to
used without register
registration
Improper storage of MS Block CSU Signage and Open
corrsive substance 505-M02-TK barricade is
drum beside 01 required
phosfate tank
Presence of woden MS Blcok JCC All wood shall Open
planks in the 520-D-003 be removed
HC+H2 rich gas
storage drum
Acytilene and MS Block DC2 Immediately On going
oxygene gas ordred to put
cylinder has been them up and
trasported layed secure with
down on the back of wire
pickup truck
Small leakage of oil MS block CSU Report to cSU On going
from the pump 520-P-001 B team
Chain block used MS Block DC2 To be changed Open
with broken safety
leash in the hook
Missing of grating ETP CPECC Cover is Open
cover of the V-dich 840-TK-002 required
drain
Missing lock-out for MS block CSU LOTO to be Open
the pump insulation 500-P-005A implemented
valve
Some steam heat 520-F-1234 CSU To be checked Open
tracing tube are
bending
Many hot steam All MS CSU Heat tracing Open
heat tracing tube are block pipe shall be
not covered which protected
could lead to skin
burn in case of
cutaneous contact
ESD buttons need All MS CSU To be reviwed Open
cover caps for block
protection
Improper indication SRU CSU LI shall be Open
in the LI of 570-TK- 570-TK- calibrated by
001A that showing 001A instrument
more than 100% team
sour water level (see
pict 01 )
Manhole of the SRU DC2 Manhole to be Open
Tank was left open 570-TK- closed
001A
Improper disposal MS Block CSU Safety signs as Open
of corrosion 500-M-002 well as proper
inhibitor drum next barricading
to the corrosion must be in
inhibitor skid place
Unsafe scaffolding MS Block CSU & JCC Modification Open
platform ( ladder 520-M-004 is required
not fixed –
incomplete working
platform)
Waste water ETP CSU 1. Fence is Open
dropped in Evap Pound required since
evaporation pound 2. Life buoy 20/10/201
mixed with naphtha to be 9
could lead to fire in provided
case of any source 3. Warning
of ignition sign shall
be installed

Non cleared muster MS Block CPECC Muster point Open

point in MS block shall be
area cleared before
unit start-up
Due to a MS Block CSU Modification On going
manufacture 520-E-008A is required
Problem, exchanger
cannot be assembled
after cleaning &
inspection. therefore
it remain hanged
Due to an increase MS Block CSU Owner Closed
of the pressure 18.2 520-C-001 firefighting
Bar in the top of used lance
column 520-C- monitor to
001,the tubing make a screen
connection of the protector from
manometer released any source of
and big leak of heating
naphtha start about Pressure
20min nonstop on dropped and
the pumps ,drum the valve has
and air cooler been closed
 Failure on manually
the PSV which used
to release at 17 bar

During our routine MS Block CSU CSU team was Closed

inspection on site 520-K-002 informed in
we notice that there the SRR3 to
was leak of H2S & check if there
H2 in the is a leak
compressor area
520-K-002 as per
gas detector
H2S:7PPm
LEL:13 %
Cleaning of ETP CSU Ordred to Closed
emerged pump filter Drain pit provide lather
without proper PPE coverall and
mask
Unsafe parking of MS block All subcon Proper parking On going
cars which create an area to be
obstacle for disginated
firefignting truck in
cas of intervention
on NHT unit
Emergency PTW 950 Unit CSU Only Closed
for H2 bullet fill up authorized
was appropved by person
imoper person on
HSE authority case
( see pict 01 -02 )
Workers are over MS Block CSU Speed limit Open
speeding especially /JCC/CPECC/Sonatrach shall be
light vehicles while respected
driving on site
Opening of close ETP JCC Immediately Closed
drain pit without ordered to
protection provide hard
barricade
around
Improper storage of MS Block CSU Proper storage Open
dangerous substance 520-M-002 & signage is
DMDS required
Waste water ETP CSU 4. Fence is Open
dropped in Evap Pound required since
evaporation pound 5. Life buoy 20/10/201
mixed with naphtha to be 9
could lead to fire in provided
case of any source 6. Warning
of ignition sign shall
be installed

A Truck was MS Block DC2 Immediatey Closed

dropped in ditch East road help to take
with key inside as out of the dich
the pictures shows and inform
,fortunately it DC2
doesn’t caused any Supervisor
harm or damage to
electrical poles
Unsafe scaffolding MS Block CSU Guardrail is Open
platform without 520-R-001 required
guardrail ( see pict bottom
01 )
Wooden planks are MS Block JCC All wooden Open
still in use on planks shall be
scaffolding structure replaced with
prior NHT & CCR steel planks
Startup
Non cleared muster MS Block CPECC Muster point Open
point in MS block shall be
area cleared before
unit start-up
Water flushing SRU DC2 Barrication & Closed
without proper signed was
barication and provided
signage
Improper storage of MS Block JCC Proper & Closed
Oxygen cylinder 520 secured
 storage is
required
Improper walkway MS Block JCC Walkway shall Closed
for welding anchor 520-R-004 be secured by
bolt plate not wire
secured
Furnace manhole MS Block JCC Manhole shall Closed
was remained open 520-F-005 be closed
since 3 day
Spill of SRU Main CSU Remediation closed
contaminated water Road of spill is
mixed with naphtha required
due to transportation
from ETP by Cargo
truck
Reactors structure MS Block JCC All wooden Closed
full of wooden 520-SC-01 planks shall be
planks removed
Grating tied with MS Block JCC Clips are Open
steel wire which 520-SC -01 required to fix since
might lead to Top side the grating 07/12/201
tripping hazard (see 9
pict 01 )
Homemade tools MS Block JCC All homemade Closed
still in use by JCC 520-R-004- tools shall be
003-002 removed from
site
Most MS Block CSU JSA/RA are Open
Commissioning required
PTW for without
JSA/RA
Waste water ETP CSU 7. Fence is Open
dropped in Evap Pound required since
evaporation pound 8. Life buoy 20/10/201
mixed with naphtha to be 9
could lead to fire in provided
case of any source 9. Warning
of ignition sign shall
be installed

Tripping hazard due MS Block JCC Material Closed

to poor arrangement 520-R- arrangement
of scaffolding 1,2,3,4 shall be done
material on the
reactors structure
Tripping hazard due MS Block JCC Material Closed
to poor arrangement 520-R- arrangement
internal material 1,2,3,4 shall be done
removed from the
reactors
Reactors inspection MS Block JCC Confined Closed
has been carried out 520-R- space
without in/out log 1;2;3;4 procedure
sheet shall be
implemented
10.
11.
More scaffold with MS block JCC All woden Open
wooden planks in 520-sc-01 planks shall be
CCR reactors 520-SC-01- removed
structure 02
Scaffolding MS Block JCC Inspection and Open
structure not 520-R-004 scaff tag is
inspected required
Furnace inspection MS Block JCC Immediatelly Closed
has been carried out 520-F- called for
without watchman 1;2;3;4 watchman and
and in/out log sheet provide log
sheet
Wooden planks are MS Block JCC All wooden Open
still in use at ISOM 510-C-001 planks must be since
unit removed 28/11/201
9
Non certified SCBA MS Block CSU & Sonatrach Certified Pending
apparatus used for 500 SCBA are
H2S sample required with
connection without Algerian
Gas Cylinder stamp
Road traffic : All site CSU – CPECC – JCC – Speed limit Pending
Workers are over Sonatrach shall be
speeding while followed
driving on site
Scaffolding wooden MS Block JCC Shall be Pending
planks kept in CCR 520 east side removed
after dismantling immediately
Wooden planks are MS Block JCC All wooden Open
still in use at ISOM 510-C-001 planks must be since
unit removed 28/11/201
9
Lack of wind sock MS Block CPECC Wind sock to Closed
be provided
Unsafe mobile RFCC JCC Guardrails to Open
scaffold without Main be installed
guardrails (pict 1 ) Piperack
Lack of access to RFCC JCC Access shall Open
the 3rd platform be provided
( pict 2)
Wooden planks are MS Block JCC All wooden Closed
still in use at NHT 500-E- planks must be
unit during strat-up 001A/B/C/D/ removed
E
Lack of wind sock Green field CPECC Wind sock to Open
in all green field be provided
Wooden planks are MS Block JCC All wooden Open
still in use at ISOM 510-C-001 planks must be
unit removed
Workers on the roof Ware house CPECC Life line shall Open
without any fall be provided on
protection system the roofing
(see attached pict ) work
Before NHT start- MS Block CPECC Muster point Open
up, Muster point in to be cleared
not yet cleared
Workers were using MS Block DC2 All dangerous Closed
improper platform PR-01 platform shall
to repair the air be removed
cooler (see attached
pict )
Drilling hole on MS Block JCC Immediately Closed
package grouting of 520-F- stopped them
the furnace which 1,2,3,4 and suspend
feeding the dry out the activity
with fuel gas with
drilling machine
During sulfiding MS Block CSU MSDS is Open
operation ,lack of required
MSDS of DMDS
Wooden planks are MS Block JCC All wooden Open
still in use at NHT 500-E- planks must be
unit during strat-up 001A/B/C/D/ removed
E
Isulation waste left MS Block JCC All insulation Open
under 500 500-E- waste to be
exchangers 001A/B/C/D/ removed
E
Scaffolding MS Block JCC Scaffold to be On going
structure was dismantle and
bended due to stress re-erected
with loading
catalyst drum ( see
attached picture )
Lack of muster MS Block CPECC Muster point is Open
point whether the required
units start-up
Lack of barrication MS Block CSU Ordred to Closed
while hot steam make warning
water flow tape around
Improper storage of MS Block CSU Proper storage Open
thiner (diluent) SRR3 with signage is
nearby the SRR3 required
entrance
After grating MS Block All subcontractor Signage has Closed
removal for PR 001 been provided
modification.worker and watchman
s cross the at workplace
barricaded area
Cigarette butt MS Block CSU/DC2 & JCC Smoking is On Going
thrown on the 520-K-001 prohibited on
grating platform site
Damaged fire MS block JCC Fire Open
extinguisher used 520-M-004 extinguisher to
with the electrical be changed
generator
Lack of sole plate MS Block JCC sole plate is Open
under scaffolding required
structure
Poor material MS Block JCC Material Open
arrangement which arrangement is
blocking the access required
inorder to clear
the access
Grating clips not MS Block JCC Clips to be Open
fixed fixed
Naphtha Filter has MS Block CSU HSE Dep shall Closed
been cleaned and 500-D-001 be informed
gasket was changed for any urgent
in 500-D-001 intervention
without any PTW
During dismantling D Area JCC Life line is Closed
of JCC shelters ,lack required
of life line while
working on the roof
Improper cable MS Block CSU Proper Closed
derivation of extra- 500-F- plugging is
long lighter using 002/003 required
tape
Poor arrangement of MS Block JCC Immediately Closed
scaffolding material 520 ordered to
material which lead arrange
to potential tripping scaffolding
hazard material
Confined space : MS Block JCC &CPECC Closed
successful cleaning 520-D-003
& inspection of the
internal vessel 520-
D-003 A/B with
support of CPECC
team
Improper Main road JCC Immediately Closed
transportation of stopped and
scaffolding tubes asked to secure
with rope
Poor arrangement of MS Block JCC Material Closed
scaffolding material 510-D-010 arrangement
on the platform A/B has been done
which block the
access
Poor housekeeping Ms Block JCC Housekeeping Open
in the east side is required since
26/10/201
9

Non respect of MS Block JCC Immediately Closed

confined space 520-F- get theme out
precaution (lack of 1,2,3,4 until they take
watchman,poor corrective
lighting inside,no action
logsheet )
Nearmiss has been MS Block JCC Immediately Ongoing
occured this GE ordred to add a
afternoon while a compressor toe board
welder was working
on a scaffolding
platform without toe
board,then 1.5 inch
pipe dropped down
Scaffolding Ms Block JCC Toe board is Open
platform without toe GE required
board compressor
Missing transom Ms Block Modification is required Toe board is Open
and ledger on GE required
scaffolding structure compressor
Homemade tools are MS Block JCC & CSU All homemade Open
still used on site tools shall be
removed from
site
Wooden planks left MS Block JCC All wooden Open
on pipe lines & steel planks shall be
structures could removed
easily burn in favor
condition during
while naphtha will
be injected
1. Scaffolding MS Block JCC 1. Scaffold Open
 platform has been 510 ISOM shall be
moved with crane dismantled
from area to other and
area with is not erected
complying to 2. Scaffold
scaffolding shall be
standard inspected
2. All component
tubes and couplers
lose its resistivity

Acetylene & SRU JCC Flash back Open

Oxygen gas arrestor is
cylinder used required
without flashback
arrestor

Loose material left MS Block CSU/JCC All loose Open

on the top of 500-F-001 material shall
furnace 500-F-001 be stored
properly
Improper disposal MS Block CSU/JCC Box is Open
of bolts during 500-F-001 required
opening of furnace
conviction section
manhole susceptible
to fall
Improper storage of MS Block JCC Gas cylinder Open
argon gas cylinder 520-SC-0101 shall be
with steel wire secured with
( picture 01/02) chain and
proper storage
Impoper MS Block JCC Immediately Closed
arrangement of Pipe Rack ordred to
scaffolding tube arrange tube
during lifting and porivde
operation without proper tagline
adequate tagline
(pict 03)
Poor management MS Block JCC Management Open
of welding cable 520-sc-0101 cable is
could damage with required
grating platform
(Pict 04)
Inaccessible RFCC JCC Obstacle to be Open
scaffolding access 530-PR-01 removed
(blocked )
Hot pipe surface MS Block JCC & CMS Signage & Open
Due to steam 520-PR-01 barrication is
blowing without any required
barrication of
signage
Due to lube oil MS Block Commissioning team To be cleaned Open
flushing ,oil was GE ASAP
flowed down on the Compressor
grating platform 520-K-001
which become
slippy
Blind was removed MS Block Commissioning team Reported to Closed
after leak test ,hot 505-D-007 Commissionin
water was flowed g night shift
team
Access blocked by MS Block JCC Access to be Open
scaffolding material GE cleared
on the grating Compressor
platform 520
Improper MS Block JCC Modification Open
scaffolding platform GE is required
Compressor
520
Forklift was MS Block JCC Immediately Closed
operated by 520-D-006 ordred to stop
incompetent person
During reactor MS Block DC2 Immediately Closed
cleaning ,water 520-R-002 ordred to stop
falling on electrical and cover
panel
Imporper MS Block JCC Must be On going
scaffolding platform 520-D- removed from
still used on high 007A/B site
elevation
Oil spill from the air MS Block Commissioning CPECC Shall be Open
compressor 510 covered with
sand
Apparent rebar on MS block Segregation Open
the ground can waste is since
JCC
(tripping hazard ) required 02/10/201
9
Scaffolidng material MS block Scaffolding
left on the GE material need
JCC Open
compressor to be removed
platform
PVC pipe appeared MS Block Shall be cut
nead furnace 500-F- JCC Open
001
Observation Area Subcontractor Corrective Progress
action
Successful MS block Mission
Absorber loading completed
of the 5th vessel
consecutive deep JCC & CPECC On going
with support of
CPECC rescue
team
Hot tubing can MS Block Commissioning Signage is Open
burn at cutanous required
contact
Cigarette butt MS block Smoking is
thrown on the GE prohibited on
compressor site
JCC & CPECC
platform wich Open
commissionng
may lead to fire
while gas has
been introduced
During the MS Block Only authorized
furnace 500-F- 500-F-001 person are allow
001 Many people inside
with are not
CPECC &
involved in the On Going
Sonatrach
operation across
the barricaded
area either
CPECC or Owner
Workers are still MS block Cell phone is
using mobile prohibited
phone on site henceforth
JCC Open
even gas has been
introduced in MS
block
Successful MS block Mission
Absorber loading completed
of the 4th vessel
consecutive more
JCC & CPECC Closed
than 9 meter deep
with support of
CPECC rescue
team
OBSERVATION RELATED TO THE COMMISSIONING ACTIVITY
Observation Area Subcontractor Corrective Progress
action
Hydrogen 950 Unit Linde gas Operation Ongoing
cylinder truck suspended until
arrived to site this they change a
afternoon then new valve
they start filling
up the 950 unit
vessels,
unfortunately,
there was a leak
precisely in the
connection valve,
so the operation
has been
suspended.

Wooden planks MS Block JCC All wooden Open

left on pipe lines planks shall be
& steel structures removed
could easily burn
in favor condition
during while
naphtha will be
injected
Metalic Hand MS Block JCC & CSU All hand tools Open
tools are still in shall be changed
use during the by bronze tools
commissioning &
startup
No protection for MS Block CSU Warning tap is Open
steam blowing 520-K-001 resuired
operation
discharging side

Permanent hazard ETP CPECC Fence and life Open

next to the buoy are
evaporation required
pound while
workers walking
on the edge
(missing fence &
life buoy )
Successful inert MS block Mission
balls loading of completed
the reactor 510-
R-001 more than
JCC & CPECC Closed
24 meter deep
with support of
CPECC rescue
team
Two Successful MS Block CPECC / Closed
Loading & 510-R-002
inspection 510-D-005
operation inside
510-R-02 25M
deep & 510-D-
005 using rope
access devices
with support of
CPECC rescue
team
Unsecured steel MS Block CMU Whipe check is Open
wire during air GE required
blowing instead compressor
of Whipe check
During furnace MS block JCC Watchman with Closed
inspection,no 500-F-01 log sheet has
watchman and no been provided
log sheet in/out
(Pict 05)

Fire hose has MS Block JCC *Sprayer to be Open

been used to 520 repared
spray the soil by *Never use fire
JCC worker wich hose to avoid
damaged the firefighting
sprayer part pressure
decrease
During the MS Block Only authorized
furnace 500-F- 500-F-001 person are allow
001 Many people inside
with are not
CPECC &
involved in the On Going
Sonatrach
operation across
the barricaded
area either
CPECC or Owner

Cigarette butt MS block Smoking is

thrown on the GE prohibited on
compressor site
JCC & CPECC
platform wich Open
commissionng
may lead to fire
while gas has
been introduced