An action is defined as critical if it is an “uncontained risk” which may delay commissioning / hydrocarbons in.
Non-critical actions still require closure, but are considered to be contained (i.e. due date is “in sight”).
16 September


Requirement Required Action/Status Cat Critical? Co Resp. Person Due Date
* The Most Basic Requirements to enable introduction of hydrocarbons as per Dag Peiffer’s email summary on 10 September
*1 Tested and operational gas and fire detection system This replaces the action B2.
Critical actions that UHDE and Sazeh need to follow up:

  1. Retype the actions from Mr Dalgliesh (Fire and gas alarm panel vendor representative) to get a soft copy and track the actions in the daily commissioning meetings.
  2. Get Drager out IMMEDIATELY to calibrate the hexane sensor that is faulty.
  3. The vendor will only return the Iran once EVERY SINGLE reservation is complete, but we can actually start up with parts of the system not yet operational. Therefore finalise the details of the test method and commissioning WITHOUT the vendor presence (i.e. before his return)
 A CRIT S
U
A		 Sani
F Peterson
P Mennell		 01 Oct
*2 Tested and operational fire fighting system
 This replaces the action H3 (but do not let H4 slip either).
Critical actions that UHDE and Sazeh need to follow up:

  1. Finalise the test method.
  2. Resolve the issues around the foam panel.
 A CRIT U
S
A		 F Petersen
Sani
P Mennell		 01 Oct
*3 Functional emergency equipment e.g. safety showers, eye wash
 This replaces the action A22
Critical actions that UHDE and Sazeh need to follow up:

  1. There is re-engineering work required on the suction line of the pump.
  2. Site check still required.
 A CRIT U
S
A		 Felix Petersen
F Safavi
Denis Bester		 01 Oct
*4 Complete disconnection and removal of all temporary electrical equipment
 Critical actions that Sazeh needs to follow up:

  1. Provide a plan for the removal of all temporary electrical equipment.
 A CRIT S F Safavi 22 Sep
*5 Implemented access control system
 Critical actions that UHDE and ASPC need to follow up:

  1. Finalise training and train the trainers.
  2. Implement the system.
 A CRIT U
S
A		 M Saleh
F Safavi
P Mennell		 26 Sep
*6 Implemented permit system
 Critical actions that ASPC needs to follow up:

  1. Continue to iron out problems with cold work, hot work, and confined space entries with audits and memos.
  2. Roll out the electrical racking out/in procedure.
 A CRIT U
S
A		 M Saleh
F Safavi
P Mennell		 Ongoing
*7 Well implemented EMS
Critical actions that ASPC needs to follow up:

  1. Close off outstanding actions from previous emergency exercises.
  2. Create a plant-based emergency management procedure to compliment the site-based procedure.
 A CRIT U
S
A		 M Saleh
F Safavi
P Mennell		 01 Oct
*8 Mechanisms for communicating safety information down the line This is a necessary extra that P Mennell added. Critical actions that UHDE, SAZEH, and ASPC need to follow up:

  1. Get toolbox talks and safety committees up and running. They will take their topics from the daily commissioning meetings.
  2. Create mail distribution groups for production and maintenance (including for Firmco).
  3. Fine-tune (augment?) the instruction book system in the control room.
 CRIT U
S
A		 M Saleh
F Safavi
P Mennell		 01 Oct
*9 All deficiencies (those listed with photographs in the addendum to the original PSSR action list) resolved This is a necessary extra that P Mennell added. We have not been tracking these, so M Saleh must forward a SOFT COPY of the lists to P Mennell for incorporation into the PSSR meetings.

Also incorporate section F (emergency management) actions into this list.		 A CRIT U
A
 M Saleh
P Mennell
A Occupational Safety and Health / Operations
A15 Sharp edges, crushing and impact points in the plant made safe Inspection Report issued and accepted. A S Salmanzadeh Closed
A19 Escape routes marked, doors not blocked or locked Sazeh to issue drawings to show where the escape routes are, and finalise the installation of the signboards.
Escape / emergency exit doors to be properly marked off on the outside.		 A S Salmanzadeh 18 Sep
A20 Gathering (Muster) points marked ASPC to finalise the design for the symbol and install at selected muster points. A A
A		 J Adams
A Naeimi		 Closed
A21 Signs in the plant Contract says Sazeh installs only escape and fire system signs (addressed in A19).
ASPC must decide what other signs it wants (PPE, Hazardous materials) and install them.		 A CRIT A H Karimi
A Naeimi		 01 Oct
A22 Emergency showers in operation, eye showers in operation Covered in “Most Basic Requirements” action *3 A Link See *3
A23 Building lighting in operation and sufficient FINAL illumination report required for the following:

  • Buildings
  • Control room
  • Substation
  • Plant areas
  • Bagging line

ASPC issued a preliminary report some time ago for the plant areas, and lux levels were too low in some places.
Also, some of the lights around the recycle gas compressor are not flameproof so must be removed for start-up, and will probably lead to even worse lux levels.
Testing to be done on Wednesday 19 September 19h00, and a report to be issued for ALL 5 areas by the next meeting.
Note that action B8 (the same thing for emergency lighting) also must be done.
See B8 for emergency lighting.		 A CRIT S
A		 Sani
H Karimi, E Grobler
 22 Sep
A24 Intercom tested and available There are concerns that the intercom system does not work when used FROM the FIELD. ASPC checked all intercoms and reported that the problems are limited to:

  • 1501 and 1502 at homogenization (faulty general call)
  • 1506 at 2nd flor extrusion (switch/knob broken)
  • Also, ASPC wants to have the numbers for calling from one field unit to another field unit(?).

Sazeh to fix the deficiencies.
This has been considered to be related to two-way radios, which are being dealt with separately.		 A A
S		 Naeimi
Safavi		 18 Sep
A27 General condition, house keeping The general situation must be improved. Especially in the ex-zones all flammable materials and also all materials which could lead to an ignition must be removed. The entire polymerization steel structure (including below the installed gratings) must be cleaned. A S
A		 Salmanzadeh
Denis Bester		 15 Sep

B 		Process Safety
B2 Gas warning system tested and in operation / Panel available Covered in “Most Basic Requirements” action *1 A Link See *1
B8 Emergency lighting available and checked, including in control rooms and power stations Sazeh has to submit inspection reports. Requirements:

  • Issue drawings to show locations of all emergency lights. These should be in all the same locations as for normal lights, that is:
    • Buildings
    • Control room
    • Substation
    • Plant areas
    • Bagging line

  • Identify all emergency lighting with appropriate symbols.
  • Carry out a live test of the diesel generator by switching all the incoming power off and see if the emergency lights come on, and check at the same time that the correct lights come one (the marked ones). Sazeh must do this since they are doing the switching. Do the test at 18h00 to see if the switching works, and leave on until 19h00 to do the lux meter readings. The test method to be approved by ASPC.

See A23 for non-emergency lighting.		 A CRIT S
A		 Sani / Khosravi
Grobler		 01 Oct
B14 Pumps checked
Mechanical seal monitor in operation
Pump documentation available 		This is an MC book issue.
Will be done system wise. Inspection reports have to be checked prior RFC. Re-categorized to A. Part of the MC-books.		 A MC Issue
B17 Fans and blowers tested and marked Safety related exhaust fans and special requirements:

  • Analyser house air intake ducting, analyser, alarm, and interlock system to be checked.
  • Manual isolation on the fresh air supply to the control room HVAC also to be checked. What about analysers on this intake?
  • Blower hold by dummy run (C-80002) that hold by EP for relay.
  • Report to be issued stating where else these special fans, blower, and exhaust fan installations / control systems exist.

Some comments from previous meetings:
Inspection reports have been not available. A system must be set up to ensure that all fans and blowers have been tested prior RFC. All process blowers (radial and axial) must be handled in the same manner like pumps.		 A CRIT S

A
U		 Safavi / Sani will meet on 15 Sep
Naeimi / Mennell
M Saleh		 22 Sep
B22 Level gauges/inspection glasses on vessels checked Inspection report required to prove that all gauges and inspection glasses have been tested prior RFC. Is this really being checked by UHDE during final P&ID checks. A MC Issue
B24 Hydraulic (unit) equipment and pipes Comments so far:
A visual check regarding leakage’s or spills has to be carried out on a frequently basis on site.
(Extruder) Vendor required.		 B MC Issue
D Electrical Engineering, Instrumentation and Control (EEIC)
Note: IPF stands for instrument protective functions and denotes an instrument that inherently limits the protection system requirements (e.g. a control valve trim that limits the sizing requirement for a PSV). Such an instrument, including its constituents, may not be changed without taking due care to ensure the protection system remains adequate.
D8 Tech. data sheets for IPF / safeguarding facilities available Operating manual, drawings and as-built docs to be made available in the control room, including for interlock and shutdown logic narratives.
U, S, A to meet on Monday 17 Sep at 15h00 to resolve this.		 A CRIT S
A		 ?
Ashoordehi		 17 Sep
D9 Alarm and Trip set points tested, IPF devices specially labeled Alarm and trip points:

  • Checked within loop check.
  • As agreed between UHDE/Sazeh the interlock check will be done during commissioning.
  • Physically test must be carried out, only wiring was tested yet.

IPF devices (control valves, orifices, sensors, and actuators), data sheets, and logic specially labeled:

  • P&ID’s already indicate IPF devices.
  • Logic has been said to be done. Who said so?
  • Data sheets to be marked up.
  • Devices in the field to be specially tagged. ASPC to design a label and install on the IPF instruments.

If necessary, consider waiting till after start-up with the IPF labeling and use the MOC procedure as protection mechanism to prevent illegal changes to IPF-instruments. Peter Mennell to enter discussions with Dag Peiffer.
Checklists for regular checks must be created. This is present in the final documentation.		 B CRIT U
S
A		 ?
?
?		 30 Sep
D11 Sensors correctly adjusted or calibrated and labeled Generally OK, since labeling, checking, and test is done as part of the loop check. Gas detection sensors are considered in action B2 above. A Link See B2
D14 Control valves set, run and marked.
• "Fail-safe action" checked
• Seat and plug checked as per data sheet 		As part of the loop check done. Does this really include the trim? A MC Issue
D15 Heating systems checked and in operation, safety temperature limiter switch correctly adjusted and checked Sazeh to issue inspection report:

  • Heat tracing for capillary pressure transmitters.
  • Heat tracing for analyser lines.

This requires heaters to be energised, and must be done before system commissioning		 A MC Issue
D16 Quality certificates available EX and quality certificates to be checked and confirmed:

  • Offshore confirmed by UHDE
  • Onshore also has been confirmed (incl. for HV cables).
  • The electrical junction box outside the analyser house does not meet the standard, and will not be accepted by ASPC. A replacement must be ordered. Check for others.
 A CRIT U
S
A		 Mohammed Saleh
Sani
Eben Grobler		 15 Sep
D17 Power supply to all safety-related facilities checked for Battery back-up and Power inverters To close this off, clarify which UPS units are where and what the requirements are for each. This requires Sani and Eben Grobler to get together BEFORE the next PSSR meeting:

  1. DCS unit UPS:

To shut down the DCS

  1. Fire alarm panel UPS:

This UPS has not been accepted by ASPC since

  1. The UPS must move to the battery room with exhaust fans, and
  2. The unit cannot be maintained since there is not enough space in the cabinet to access the wiring.

Also the battery back-up is no longer operable and must be replaced.

  1. Other UPS:

??? 		A CRIT S Sani 22 Sep
D18 Electrically driven motors – set point of over current trip correctly adjusted. Diagrams available, Displays in operation, Motors labeled Motor trip set points:
Sazeh to bring the vendor for all 6.6 kV motors on 16 Sep. Peet le Grange to be present.
Vendors are not required for the 400 V motors. But the tests must be done for all motors, and especially a bump test must be carried out. Inspection report for motors with free run test available.
Main incomer trip set points:
Peet le Grange to supply survey findings for main incomers to Sazeh. Sazeh to fix shortcomings.		 A CRIT S
A		 Sani
Peet le Grange / E Grobler		 16 Sep
D19 Motor valves run and set; marked The motor valve on the extruder must be run and checked by the vendor, JSW.
Awaiting vendor presence.		 A S ? ?
D20 Lighting and emergency lighting of entire plant tested Link See B8
D21 All motors and actuators checked for cut-off criteria and marked Only software-check done. Especially for IPF-functions (e.g. ESD) mandatory.
No marks found. (during Commissioning)
Pending (no clear statement from Sazeh)
Commissioning UHDE.
Also prepare to do a full on mock switching of the main ESD buttons. Do for ESD to see that the ESD switched work. Before hydrocarbons.		 A S ? Commissioning
D22 All electrical equipment (distributors etc.) provided with warning signs, marked and secured against being touched Minimum requirement from Sazeh:
Push buttons on (all) local panels are to be labeled with tags AS WELL AS descriptive text.		 B S Sani 01 Oct
D23 Sockets checked and marked Minimum requirement from Sazeh:
Installation report, punches, damages, function of safety switch.
Labeling to be completed.
Uhde to carry out a cross check for RCDs/sockets.
This is being done, and lists are up and running?		 A U
S		 ?
Sani		 01 Oct
D24 Access to switch room, rack room clear All switch room/rack room doors not properly labeled. Label doors. Exit signs. A S Sani 01 Oct
D26 Cables protected against fire Cables of fire fighting system have to be checked to make sure they are all of same type.
Certificates have been checked in Tehran office.		 B S Sani 22 Sep
D27 Valves with handles: protected against accidental opening/ closing B Closed
E Environment
E3 Plans of foundations and underground pipes available and "as built" SAZEH to check and submit to Uhde documentation available. B S ? MC issue
E6 Noise prevention observed; measurements conducted, specifications observed! SAZEH engineering must submit documentation. A noise survey must be carried out during commissioning phase B S Salmanzadeh ?
E10 Check for leaks of the ducts for waste water subject to treatment Inspection Report to be checked. Separation rainwater should be checked by SAZEH. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed
Refer to mc book building duct station		 B S
A		 ?
?		 ?
E11 Condition of the plant surfaces (joints, cracks) Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed		 B S
A		 Shahani ?
E12 Retention possibilities for leaking liquids hazardous to water (oil separator, sewers, slop tanks etc.) Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed		 B S
A		 Larizadeh, Salmanzadeh, Shehni ?
E13 Lining/coating of pump sumps and channels Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed		 B S
A		 Mohamadi
?		 ?
E14 Collection of drips of substances hazardous to water from pumps/ Compressors etc. Inspection Report to be checked. An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU
Pending. To be discussed		 B S
A		 Larizadeh
?		 ?
G Explosion Protection
G1 Explosion protection documentation available and up to date
Confirmed by ASPC 		Only Ex-Zone plan available.
Uhde to check in SAZEH engineering documentation and to be cross checked by ASPC.		 Link See D16
G2 Hazardous zones are durable signed in pant Sazeh still to install sign boards, yellow with black triangle and text “Ex”, on all entries of Ex-Zones in both polymerization and extrusion areas. Sazeh will provide drawings of the stands before installation.
Also install red line on ground around polymerization area (with distinct distance to building).		 A S Salmanzadeh 01 Oct
G3 Lightning, earthing, bonding protection documentation is available and test is certified Not checked during PSSR. Actually a short cut between instrument and electrical earthing was reported. Ongoing punch list. A S Sani MC Issue
G4 Arrangements against electrical charging are taken No inspection reports available.
Not all flanges of powder transport/storage system are equipped with earthing strips.		 A S Sani 22 Sep
G5 Certification for mechanical and electrical devices are available and manual is available in English language Link See D16
G6 Test certification for electrical installations is available according to local requirements A MC Issue
G7 Test certification for non electrical devices is available according to local requirements Is this for anti-static shoes?
Refer to Peiffer / Jost to obtain clarity.		 A U
A		 Saleh
Mennell		 18 Sep
G8 Verification for intrinsically safe electrical circuits are available. Document submitted to UHDE Germany by Mr Khajehzadeh. This calculation was not accepted. This must be resolved URGENTLY.

Copy of Ex-Certificates for electrical/instrument equipment should be added to loop check documentation and is recommended for every intrinsically circuit.		 A CRIT S



U		 Khajehzadeh



Schoeman
 17 Sep



MC Issue
G9 Installation of „explosion protection by means of electrical devices is available, tested and documented See Basell about this? Link U M Saleh 18 Sep
G11 Protection systems correctly installed G-111: Check required if power sockets in polymerization area are of the correct type. MC ISSUE
To be checked if locks have to be installed to avoid usage of non-intrinsically safe power sockets without permission. Not required.
G-112: Video-Boxes/installation not according to explosion protection. Electrical installation not according to regulations. Must be removed! Found at several places. CLOSED
G-113: Ex-i installation not correct.
To be checked for all sensors of same type. SCHOEMAN TO REPORT BACK
Being sorted out internally, as are all the other deficiencies.		 A U Schoeman 22 Sep
G12 Maintenance-, test manuals, and test schedule, for protective systems (e.g. flame arrestors, rotor conveyors) available ASPC asset integrity group to complete. This requires final documents, which ASPC mostly has. B ? A Eben Grobler 30 Sep
G13 Primary protective systems according to explosion document are installed and tested (e.g. inerting system, air ventilation) See Basell
This is an MC Book issue, and it requires that the installation is tested.		 B ? U M Saleh 18 Sep
G14 Test documentation of primary protective systems available See Basell B ? U M Saleh 18 Sep
G15 Special, additional protective systems according to explosion document installed, tested and documented see G-1. Not checked while explosion document not available.
Explanation by Basell
Is there anything over and above the analyser house? PM and NJ to check and then get the docs checked.
salmanzadeh		 A ? U
S		 M Saleh
?		 18 Sep
G16 Documentation of devices with special certification available Available in vendor documentation. For offshore ok, for onshore to be checked by SAZEH
See Basell.
To be checked with SAZEH refer to sazeh final document		 ? S M Saleh 18 Sep
H Fire Protection / Risk Prevention
H3 Spray water, deluge system, foaming system and/or other auxiliary systems installed and tested Covered in “Most Basic Requirements” action *2 A Link See *2
H4 Extinguishers, fire blankets sufficiently in plant, control room, rack room, switch room available This is an MC issue but Sazeh must issue an inspection report and confirm against the specified requirements. We do not currently have any fire blankets, but Sazeh claims that the extinguishers are on site (pressure indicators?).

Fire blankets are not in Sazeh scope, and must be supplied by ASPC.

Checklists of these critical items must be incorporated into the precomm checks.		 A CRIT S




A


A		 Salmanzadeh




Karimi


Mennell		 22 Sep




01 Oct


30 Sep
H6 Fire protective insulation of constructions and vessels in place Currently this is believed to be required only at the Poly extension structure. An inspection report for the coating was completed, and issued to UHDE. Uhde to confirm.
Sazeh engineering also to state where else fire resistance has been specified in the construction (besides the structure). ANSWER - There is nothing else.
refer to MC book poly, system 9003.		 A U M Saleh MC Issue
H7 Fire retarding sealing for piping and cable lead-through correctly installed Final check pre commissioning to be done by Sazeh. A MC Issue
H8 Sufficient fire resistance of constructions for fire protection in place Link See H6
H9 Fire protective doors and flaps correctly installed Sazeh to agree with UHDE what to do about the co-catalyst burn-off pit. The design is not considered satisfactory by Basell – follow up required. A S
 F Safavi (speak to N Jost) 22 Sep
H10 Smoke and heat venation/hoods in place and in function Sazeh to state where these are – THERE ARE NO HOODS - and submit an inspection report to Uhde prior RFSU. A S Salmanzadeh 01 Oct
H11 Escape routes meet legal requirements Site safety plan to be checked. ASPC and Sazeh will define the details. To check Engineering Documentation. B S Salmanzadeh ?
H13 Water screen with gas warning facility in operation; CO2 flooding available An inspection report has to be prepared by SAZEH and to be sent to Uhde prior RFSU.
To be clarified by Basell		 B S Sani ?