FORM D: HAZARD STUDY 4 REPORT

THE INFORMATION ON THIS FORM IS CONFIDENTIAL TO JOHNSON MATTHEY PLC AND SHALL NOT BE DISCLOSED TO A THIRD PARTY WITHOUT PRIOR WRITTEN PERMISSION.
Project No.: Title: NER- Meeting No.: 01
a) 11kV panel (VCB)
HAZARD b) Transformer
c) MSB4
STUDY 4 d) SSB-CSF
e) SSB-batching
Author: Mohd Aiman File: Meeting Date: 20-Jun-23

Drawing Drawing Revision

Title: No.: : 00

Team Members (name and role): Issue No:

Responsibility for progressing actions:
Sahril Azraf:HS4 Leader
Jaya:PM Approval for issue:
Fareez:CM
Aiman:CCM Action Review Date:
Shahrir:Production HOD Signed:
Ruben:PE
Hanafi:AE
Haikal:CE Date:
Rifdi:QAQC Lead
Nadirah:QAQC

No. Item Requirement Comment / Action Required Action By

1.1 Installation Check pipework, valves, instrumentation configuration Verified By MHT QAQC, Pending punch list clearance RIFDI
(See also HS4 Installation and support against P&ID's and isometrics?
checklist)
Update P&ID to reflect changes and ensure suitable
management of change system has been used and
hazards suitably assessed.

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FORM D: HAZARD STUDY 4 REPORT
1.2 Check equipment labelling, lagging and valve Verified By MHT QAQC NADZIRAH
numbering, testing and labelling of stop and start
buttons and isolators?

1.3 System followed to ensure correct materials of Verified By MHT QAQC RIFDI
construction used?

No. Item Requirement Comment / Action Required Action By

1.4 Leak check vents where practicable to confirm Verified By MHT QAQC RIFDI
integrity

Confirm absence of lute sections / traps where liquid

may accumulate.
2 Relief Systems Correctly installed and documentation to approved Emergency vent
company and local site standards?

3.1 Trips and Alarms All commissioning checklists completed? To be verify before SAT Activity HAIKAL
(Commissioning Team to
check:)
3.2 Datasheets and test schedules in place? SAT Procedure HAIKAL

3.3 The practicality of test methods? SAT Procedure HAIKAL

3.4 List of persons responsible for testing in place? Asses by E&I(JM) HAIKAL
Hanafi,Ikhwan,Haikal,INEA
3.5 Procedure in place for control of trip defeats? Site procedure will be follow. SAT to be perform during HAIKAL
shutdown.
3.6 Has the Functional Safety Assessment (FSA) been SAT Procedure-Interlock safety assessment HAIKAL
completed?
(mandatory if SIL-rated trips are installed)

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FORM D: HAZARD STUDY 4 REPORT
4 Restrictor orifices or other Check in place, labelled, documented and system N/A RIFDI
flow restricting devices installed to sustain?

5.1 Critical Machines / Commissioning inspections carried out? Verified By MHT QAQC,Pending punch list clearance RIFDI
Pipelines
5.2 Schedule of Protective Systems and Inspection in N/A RIFDI
place?
5.3 Operating and maintenance instructions in place? Yes,as per vendor instruction RIFDI

No. Item Requirement Comment / Action Required Action By

5.4 Check pipe / cable penetrations through external walls N/A RIFDI
are sealed where required.

6 Inspections Check availability of equipment manufacturers and Yes,Refer FAT report RIFDI/HAIKAL
independent authorities’ test certificates?

7.1 Operating Instructions and Written and validated for normal operation, start-up, Refer Functional Design Specification(FDS) document:4014- INEA
Maintenance planned and emergency shutdowns. Also, special MH-J313-ME-STD-1533
maintenance and decontamination procedures if
appropriate.

7.2 Log sheets developed (if appropriate)? INEA

7.3 Requirements of Hazard Study 3 implemented? Yes AIMAN

7.4 Task risk assessment completed (if appropriate)? Risk Assessment: (EHS-MS-03-01-F26) AIMAN

7.5 Commissioning plan available? Yes,SAT Procedure AIMAN

7.6 Systems for control of materials used e.g. gaskets, N/A AIMAN
valves, instruments etc?

7.7 Check oxygen levels in inerted ovens / equipment N/A AIMAN

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FORM D: HAZARD STUDY 4 REPORT

8.1 Control of Substances
Hazardous to Health (in
UK, COSHH Regulation
Requirements)
8.2
Assessments complete and in place? (Including N/A AIMAN
engineering materials such as lubricants, fibrous
insulation or packing, cleaning solvents etc.)
Control by engineering means implemented? N/A INEA

8.3 Monitoring schedule in place? N/A AIMAN

8.4 LEV checks on extracted systems carried out? N/A AIMAN

Including: containment systems; fume cupboards;

dust booths; extracted cabinets or bays; flammable
storage cabinets.

No. Item Requirement Comment / Action Required Action By

9.1 Control of Major Accident
Hazards if appropriate
(1999 Regulations)
9.2
Assessments complete and in place? N/A AIMAN
Authority concerns resolved? Emergency Vent-Chimney :DOE Notification AIMAN
Process Exhaust Air Cooler :CF Pending from DOSH

10.1 Noise Meets specification (may be done after chemicals To be verify during SAT AIMAN
admitted)?
10.2 Monitoring schedules in place, zones marked? N/A AIMAN

10.3 Ear protection? N/A AIMAN

10.4 Alarm levels set to provide audible warnings without N/A AIMAN
excessive and disrupting nuisance noise

11.1 Environmental Permitting Assessments complete & authorisations in place? N/A AIMAN
/ Effluents / Waste
(gaseous, liquid and solid)

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FORM D: HAZARD STUDY 4 REPORT
11.2 Monitoring schedules in place? N/A AIMAN

11.3 Addition to Critical Environmental Equipment Register? N/A AIMAN

11.4 Ownership and responsibilities defined? N/A AIMAN

11.5 Systems for disposal of samples, spillages etc. N/A AIMAN

defined?
12 Ionising Radiations Added to Works list and monitoring schedule in place? N/A AIMAN

13 Key Isolations Accessibility, operability and labelling of key isolation N/A AIMAN
valves checked?

No. Item Requirement Comment / Action Required Action By

14.1 Emergency Power, Check for satisfactory operation? Existing System IKHWAN
Services &
Communications
14.2 Test schedules in place? Existing System IKHWAN

15.1 Training Programmed complete, validated and records in place Verify by Hanafi AIMAN
(should cover operating & maintenance personnel)?

15.2 Training programmed for contractors agreed? N/A AIMAN

16 Computer Software Validation checks completed? Verify by INEA AIMAN

17.1 Control of Modifications System to control in place? New system at existing process layout AIMAN

17.2 Modifications hazard studied (if appropriate)? N/A AIMAN

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FORM D: HAZARD STUDY 4 REPORT
17.3 P&ID’s updated and indexed? Latest: 4014-MH-J313-ME-PID-1547 AIMAN

18 Emergency Procedures Confirm that any necessary changes have been made Existing System AIMAN
to plant, site or off-site emergency procedures. Have
the procedures been practiced?

19 Other Site Procedures Do other site procedures need to be modified and has N/A AIMAN
this been done?

20 External Approvals Review status? Emergency Vent-Chimney :DOE Notification AIMAN

Process Exhaust Air Cooler :CF Pending from DOSH

21 EHS Dossier Established on plant and up to date? N/A AIMAN

(SDS for engineering materials also included in the
Plant Operating EHS Manual)
22 Construction Handover Is handover procedure working effectively? Verified AIMAN
(QA)
23 Plant Information Hazard data sheets, P&IDs, plant instructions, incident Existing Layout AIMAN
book and plan of emergency assembly points all
available?

24 Actions Outstanding An inventory of outstanding actions from previous Yes, as per “CSF Line Expansion-HAZOP Worksheet”
Hazard Studies? Note:
1)Counterweight damper (DP-01) at fresh air line 18”-
XX10004-01SD0S02 are not apply on this system
commissioning due to unreadiness of the items at site.
2)LEL Analyzer (AIT-1001/01 and AIT-1001/02) at Process
air from Oven 2&3 (12”-XX10002-01SD0S02_1-IH & 12”-
XX10003-01SD0S02_1-IH) are not apply on this system
commissioning due to unreadiness of the item at site.

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FORM D: HAZARD STUDY 4 REPORT

Project Title Meeting

HAZARD No.: : No.:
Author: File: Meeting
STUDY 4 Date:
INSTALLATION Drawing Drawing Revision
Title: No.: :

Team Members (name and role): Issue No.: Responsibility for progressing actions:

Approved for issue:

Signed: Action Review Date:

Date:

No. Item Requirement Comment / Action Required Action By

1 Pipelines Layout – avoid trip / head hazards RIFDI

Labelling – directional arrows
Pipe size
Materials of construction
Bolts tight in flanges
Size of bolts in flanges
Correct number of bolts present in flanges
Earth bonding straps (grounding)
All joints (gaskets) in place
Insulation
Heat tracing
Slopes on pipe runs
Flange splash guards
Missing pipe sections
Blanks / spades in line
Pipework supports
- stops removed / springs tensioned
Interconnections to existing plant

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FORM D: HAZARD STUDY 4 REPORT

No. Item Requirement Comment / Action Required Action By

2 Vents and Drains Location

Orientation
Blanks / locks on drain valves
Flame arrestors fitted
Height available under drains

3 Valves Access – position

4 Other Pipefittings
Size
Orientation of valve
Handles correct location / rotation
Identification / valve labelling
Correct type
Correct materials of construction
Key interlocks (and system for
keys) Autovalve actuators /
indicators Ensure valves open /
close
Temporary isolations (spades, skimmers)
Filter / Strainers installed / orientation
- strainer elements in place
Orifice plates correct size / position /
labelled. Covered by maintenance.
Non return (check) valves – right
way Pressure relief valve – rating
Pressure relief valve – routing
Rupture discs in place- correct rating
Pipe tracing installed / connected
Sampling and access to sample points
Hoses / couplings

No. Item Requirement Comment / Action Required Action By

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FORM D: HAZARD STUDY 4 REPORT
5 Driven Equipment
6 Plant Equipment
7 Road / Rail tanker
unloading / loading
No. Item
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Guarding
Correct type and nameplate
Direction of rotation
Location of controls, isolation
Emergency stop buttons / pull wires
Lubrication
Transmission belts
Correct design and nameplate
Tank cleanliness
Standard of Painting / finish
Insulation
Access (e.g. to access ports)
Ergonomic issues
Maintainability and access
Trip hazards
Protection / crash barriers / bump stops /
bollards
Tanks etc secured down
Transit holes filled
Labelling – pipes, tanks
etc
Equipment in correct position
Grounding connections
Hose connections, draining, storage
Containment on roadway
Driver facilities
Access to top of tankers
Tanker way in / out route
Barrier / immobilisation system
Wheel chocks
Requirement Comment / Action Required Action By
FORM D: HAZARD STUDY 4 REPORT

8 Instruments All instruments installed

Locations correct
Positions suitable
(e.g. length either side of flow sensor)
Access for operation
Access for maintenance
Identification and labelling
Safety interlocks
Suitable for area classification
Local gauges all fitted

9 Utilities List all utilities – incl. treatment systems

All correctly connected
Fire protection systems
LEV flow / suction
Separation of services electrical / IT / alarms

10 Electrical Equipment Identify High and Low voltage systems

Correct Zoning and type
Signs of incompleteness
Electrical connections as loop diagram
Sealing of cabinets etc
Condition of MCCs etc
Earthing (Grounding) correct
Cable trays supported, protected
Shut down buttons
Lockable switches
Isolators present and clearly marked
No loose / unconnected wires
All switches accessible
Labelling

No. Item Requirement Comment / Action Required Action By

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FORM D: HAZARD STUDY 4 REPORT

11 Control Room Accessibility to local control panels

Visibility of control systems
Control Room ergonomics
Control room environment
Validation checks on software complete

12 Containment Floors sloped correctly to drains / sumps

Drains (drain covers) in place
Secondary containment (bunds, kerbs,
dykes etc) integrity
Signs of leaks
Drip trays and spill kits

13 Safety Equipment Safety Showers

Eye wash points
Fire fighting equipment
Fixed fire protection equipment
Available PPE / storage
Hand rails in place where needed
Signs and labels
Emergency stops – protected

14 Major Accident Hazards Assessments complete and documented

Process Safety Required controls in place

Management
Concerns from enforcing authority resolved

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No. Item Requirement Comment / Action Required Action By

15 Buildings Fabric to specification

Lighting
Floor finishes – friction
Ease of access
Walkways clear / marked
Elevated flooring secure
Working platforms
Stairs and ladders
Handrails, mid rails, kick plates etc
Other ergonomic issues
Access roads
Vehicle / pedestrian segregation
Fire exits and access – routes
clear Standard of decoration /
painting Ventilation / air
conditioning Toilets / amenities /
seating Loading bays / docking
stations Fork lift truck access

16 General Housekeeping
– remaining construction materials
Access to tank tops
Lifting equipment / hoists
Security systems
Quality Control equipment
Is SOP physically possible
Commissioning procedures
Commissioning and test records
Telephone / Tannoy / data points

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