PSSR for C2 CRACKER AFTER SHUTDOWN DATE:

Prior to start up or gas in, the following will be verified as minimum to ensure safe start up.

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ACTION RESPONSIBLE VERIFIED COMENTS
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General Items
All TSR /MOC are signed off as per procedure and
1
declared ready for start up.
All permits to be signed of except that has no safety
2 conscience on the safe start up
( painting, scaffolding ex)
3 Blind removed as per blind list.
Gaskets quality to be checked, no old gaskets, no
4
double gaskets, correct gasket
No short bolting, stainless on mild steal, flanges
5
evenly tightened , all bolts tightness tested
Ensure proper isolation to surrounding systems and
6 inform all parties that nitrogen purging is to
commence on the system.
Nitrogen purge to atmosphere and O2 test.( no
7
purging to flare before O2 free)
Nitrogen stand test (2 hrs under nitrogen pressure
8
without any pressure drop).
All flanges to be soap test during the nitrogen stand
9
test.
System is purged, moisture free as per procedure.(
10
only relevant to cryogenic systems)
All hoses and temporary N2 lines have been
11
removed
Verify flare header condition and then ensure that
12
PSV are in place and locked open
Control valve stroke tested with block valves still in
13
closed position.
Instrumentation lined out and verified that it reflects
14
ambient conditions, nitrogen pressure conditions ex.
ESD tested on the system. All ESD valves has closed
15 or opened according to trip logic when tested in trip
condition and in normal condition.
All ESD are in normal condition according to startup
16
procedure.
17 Low point drains capped.
All loose materials is removed and area is clean and
18
ready for startup ( housekeeping )
All cranes, welding machines, trucks, electrical
19
lights, ignition sources are removed prior startup
Line out of all valves according to start up conditions
20
and operating procedures.
Soap testing to be repeated during pressurization
21
with process gas (normal operating pressure).
Soap testing to be repeated during cooling down to
22
normal operating temperature)
23 Cold bolting of flanges to be checked during start up.
Items Related to DCS
1 All control valves was stroke tested and confirmed
2 All ESD was simulated and tested.
 All control valves was confirmed in the correct
3
position( close or open)
All system was instrumentation reflex the correct
4 current scenario, no flow, ambient temperature and
nitrogen pressure conditions.
Safety conditions before gas in
Flare system ready
• All opening is checked to be closed on
flare system
• Flare system stand test is done with N2
• Soap test is done with N2
• All system are declared O2 free before
• Flare system is purged with N2
1
• Flare system declared O2 free
• Offsite confirmed system is O2 free
• Offsite confirm all work on flare system is
complete
• Flare valve is opened to flare
• Nitrogen purge is open
• Offsite confirm that Pilot burners are lit.
2 All roads around C2 Cracker is closed during start up
3 All surrounding plant are informed of start up
4 UPS tested and ready
5 Emergency generator tested and ready
6 Fire equipment back in position and ready
7 Fire ring pressurized and ready
8 Spray water ready
9 All alarms tested and ready (gas detector and…)
10 Sea water system ready and commissioned
11 Cooling water system commissioned and ready
12 Emergency load speakers, is tested and ready
Items Related to Shift Supervisor
1 All operators has the required radios
Night shift was send home to come out 12 hrs prior
2
to shift.
3 Full shifts available for day and night shift
Maintenance department has arranged for night
4
shift
Standby maintenance for night shift, electrical,
5
instrumentation and rotary.
All electrical equipment is bump tested before start
6
up to ensure correct rotational direction