Precommissioning General Safety

Shell E & P Ireland Ltd
Corrib Project Onshore Gas Terminal CMC
Pre-Commissioning General Safety Procedures
File No. 011142.71.510 CMC Document No: 011142-71-PR-0015

SEPIL Doc. No. COR-10-011142-71-PR-0015
CURRENT ISSUE
Issue No: A Date: 6/7/05 Reason for Issue: For Review and Approval Customer Approval
Sign-Off Originator Checker Reviewer Approver (if required)
Print Name
Signature
Date
PREVIOUS ISSUES (Type Names)

Issue No. Date Originator Checker Reviewer Approver Customer Reason for Issue
PM/FW Shell Corrib Project Team Dublin Ireland T +353 1 404 0700
F +353 1 459 9785, E [email protected]
/conversion/tmp/scratch/481919196.doc Page 1 of 25
Shell E & P Ireland Ltd 011142-71-RP-0016 Issue A
Corrib Project Onshore Gas Terminal 6 July 2005
CONTENTS
1. PURPOSE 4
2. SCOPE 4
3. REFERENCES 4
4. RESPONSIBILITIES 5
4.1 Construction Manager 5
4.2 HSE Manager 5
4.3 Pre-Commissioning Superintendent 5
5. HAZARDS IN PRE-COMMISSIONING 5
5.1 General Conduct of Work 5
5.2 Safe Conduct of Specific Types of Work 7
6. SITE CONTROL OF PRE-COMMISSIONING HAZARDS 10

6.1 Planning and Procedures 10
6.2 Pre-commissioning Site Safety Induction 10
6.3 Safety Officers for Pre-commissioning 11
6.4 Job Specific Safety Briefings 11
6.5 Notices and circulars 11
6.6 Housekeeping 12
6.7 Pre-commissioning Safety Checklists 12
6.8 Permits To Work 16
6.9 Personal Protective Equipment (PPE) 16
6.10 Risk Assessment 16
6.11 Supervision and Worksite Inspections 17
6.12 Information to Others 18
6.13 Site Identification and Isolation of Live Systems 18
6.14 Electrical Safety. 19
7. CONTROL OF SPECIFIC ACTIVITIES 19

7.1 Vessel and Confined Space Entry 19
7.2 Line Flushing and Blowing 20
7.3 Line Drying 21
7.4 Low Pressure Air Tightness Test 21
7.5 Assurance Air Blowing 21
7.6 Control of Blinds and Isolations 22
7.7 Introduction of Nitrogen 22

7.8 Guidelines for Nitrogen Purging General Safety Precautions 23
7.9 Precautions for High Pressure Nitrogen Tightness Testing 23
1. PURPOSE
The aim of the Pre-commissioning General Safety Procedure is to familiarise
and guide CMC and Contractor personnel in the safety requirements for carrying
out pre-commissioning activities on the Corrib Project Onshore Gas Terminal.
The document also contains information and guidelines on permit to work

requirements to be applied, and how to plan, prepare for, coordinate and
implement pre-commissioning activities safely. It considers the impact of pre-
commissioning work on all personnel carrying out construction and other work in
the surrounding areas.
The overall objective of this procedure is to develop a consistent understanding

and application of safe working practices for the pre-commissioning work to be
performed on the greenfield site.
2. SCOPE
This document describes good working practice, general safety guidance, and
defined requirements for carrying out pre-commissioning activities on the CMC
pre-commissioning site for Corrib Project Onshore Gas Terminal. These
principles or their practical equivalents will be applied during offsite module
precommissioning activities.
Where work is carried out at Contractor prefabrication sites, or where work is

interfaced across project site responsibility boundaries, equivalent standards are
to be applied to ensure consistency.
When instructed, safety control methods will be amended to comply with the
stipulations of SEPIL for any work to be carried out within the Corrib Project
boundary fence.
These precommissioning safety measures do not intend to give detailed or rigid

direction for unique tasks. Specific pre-commissioning precautions pertaining to
the unique requirements of a particular System will be covered by specific pre-
commissioning method statements, safety checklists, toolbox talks or other
workforce direction.
3. REFERENCES
Work Site HSE Plan
Permit to Work Procedure
Generic Pre-commissioning Procedures and equipment
Control of Pre-commissioning Isolations
Electrical Safety Rules EA-082

C01
Electrical Safety Procedures ES/260
4. RESPONSIBILITIES
4.1 Construction Manager

The Construction Manager has overall responsibility to implement the Worksite
HSE Plan, which includes management of the pre-commissioning phase up to
project Mechanical Completion acceptance. Refer to the relevant sections of the
Worksite HSE Plan.
4.2 HSE Manager

Reporting to the Construction Manager, the HSE Manager will liaise with pre-
commissioning personnel for general site safety control during implementation of
pre-commissioning work. He will co-ordinate site safety inductions appropriate to
the late phase pre-commissioning activities for personnel who will be involved in
or interfacing with pre-commissioning and commissioning work. He will review
safety and hazard assessments contained within pre-commissioning procedures
and method statements.
4.3 Pre-Commissioning Superintendent

The pre-commissioning superintendents will co-ordinate the planning and
scheduling of CMC pre-commissioning work, and interface with any Clients
existing operations and other contractors to eliminate safety and environmental
risks at the activity and contractor interfaces. He will carry out daily HSE
inspections of all pre-commissioning work. He will direct, review and approve
method statements and task hazard assessments produced by CMC pre-
commissioning engineers and subcontractors, and as required by site hazcon,
commissioning hazard identification and hazard assessment requirements.
5. HAZARDS IN PRE-COMMISSIONING
5.1 General Conduct of Work

Pre commissioning and commissioning work involves inherent hazards which
are not normally experienced in a construction site environment where the
achievement of physical erection is the overriding objective. In order to obtain
the target schedule for the Corrib Project Onshore Gas Terminal all of the pre-
commissioning, and some of the early commissioning works will have schedule
overlap with construction erection works, and will take place on a construction
managed site. There will be a spatial overlap where both construction personnel
and precommissioning personnel will simultaneously work in the same area.
The management of the hazards associated with the above philosophy of works
will recognize the possibility of either construction or pre-commissioning
personnel being exposed to the hazards associated with the activities of the
other. The potential for exposure to hazardous situations is further increased by
the high site population and overlapping but independent multiple workfaces.
Pre-commissioning work is the essential bridge activity between material

erection and its dynamic functionality. It must directly interface with erection
work, commissioning testing, start-up, and also with any existing operating
facilities. The personnel involved in pre-commissioning site work need to
demonstrate an understanding of the constraints imposed by all of these
interfaces, through the safe and efficient conduct of their work.
Pre-commissioning hazards incorporate all of those hazards normally managed

in a construction environment by construction HSE personnel. In addition to
these, extra hazards will be present as a result of commissioning work.
The pre-commissioning workscope on the Corrib Project Onshore Gas Terminal

involves the following types of work:-
 Punchlisting against specification for Mechanical Completion
 Review of installed facilities for safe operability and maintainability
 Ensuring plant integrity for subsequent commissioning scope
 Planning system and area MC completions for effective commissioning
 Flushing and cleaning using water or air
 Energised testing of Electrical Distribution
 Inspection of plant internals for serviceability
 Loading certain chemicals, molecular sieves and other inventories
 Equipment Inspections for serviceability
 Preparation of rotating equipment and ancillaries
 Local use of chemicals, nitrogen, flushing oils, lubricating oils
 Use of temporary equipment and construction plant
 Control of isolations for safety and conservation
 Internal preservation
 Use of flow, pressure and temperature
 Air blowing through process vessels and piping
 Alignment and leak testing
 Chemical cleaning (if required)
 Use of normal utility water and air supplies
 Testing of instrument items for functionality
 Uncoupled running of equipment drivers
 Tightness and containment testing
 Control and ESD System interface functionality
The above work focuses on preparing operational configurations of the facilities,

rather than on a specific location or a specific material discipline. However the
work takes place in a non-operating environment and will introduce potential
hazards for those site personnel whose primary focus is on a specific discipline
in construction or within a rigid geographical boundary. Pre-commissioning
personnel must be aware of the level of insight and focus of others in order to
control the safety implications of their work.
Pre-commissioning excludes the following categories of work, which will take

place in an operationally controlled environment during commissioning.
 Process flowing of HP nitrogen
 Running of major rotating equipment
 Circulation of liquids or gases using permanent pumps, compressors.
 General purging and gas freeing of plant
 Introduction of bulk hydrocarbons for testing
 Introduction of normal process chemical inventory or normal feedstocks.
5.2 Safe Conduct of Specific Types of Work

To meet the schedule it is inevitable that Mechanical Completion by systems will
involve the phasing of the completions of erection and precommissioning. Some
systems will commence and complete their pre-commissioning before
construction work has ceased locally, thereby introducing the elements of
potential risk as indicated below. The assessment of risk for work to precede,
needs to take into account these additional hazards and the personnel involved
should be aware of these effects:
 Effects on those not carrying out the work, but working locally under
different supervision and work permit requirements. A worksite that was
safe for all site personnel to work in and pass through in the morning
may not be so in the afternoon. The hazards in any part of the
construction site working environment are continuously changing,
especially during the pre-commissioning period.
 Work on unfinished plant. Most pre-commissioning work on piping and

equipment takes place before the final reinstatement of all components.
The security of mechanical support of unfinished equipment and
unfinished approaches to access ways may be well understood by
construction personnel performing the installation, but not to pre-
commissioning personnel. Pre-commissioning work requires close
liaison with construction disciplines to prevent oversight of access
safety and structural integrity.
 Sudden or continuous noise may be generated by pre-commissioning

activities. This has obvious site control implications on environmental
and personnel protection issues. Where a high level of pre-

commissioning noise is anticipated, the Corrib Project HSE personnel
should be provided with adequate notice to ensure that any affects on
the community relationship can be evaluated and controlled. A sudden
release of noise can have a disconcerting influence on non-involved site
personnel. It is best to provide warning and safety cover for such
events, to avoid sudden noise being interpreted by the general
workforce as emergency or out-of-control situations.
 Release of pressure. This may be from a much larger enclosed volume

than normally experienced in a construction environment. High volume
air releases at relatively low pressure may move heavy items in the
exhaust path. Dump flushing of large piping systems can have a similar
effect over a much wider area than anticipated.
 Projectiles are a risk when air blowing sections of pipeline for cleaning.
Large debris exiting form a blow exhaust point is a significant hazard
and can cause personnel injury and plant damage. Suitable cages or
muzzles are an effective precaution.
 Falling objects. Pre-commissioning work can set up vibrations. Checks

are needed for unsecured items before commencing work.
 Control of loose materials and worksite housekeeping. It is important to

maintain access and escape routes during pre-commissioning.
Continuous housekeeping and an area ownership philosophy will
become more prevalent as pre-commissioning advances and erection
work completes. As a safety control measure, the in-plant storage of
material will be minimised.
 Release of energy. High velocity flushing, blowing or pigging can set up

reactive forces in piping or equipment which is not yet permanently
supported. Piping may move causing damage or injury in locations
remote from the blow inlet or outlet.
 Low pressure leak testing can dislodge and accelerate small fittings or
tubing and cause injury. Ensure temporary fittings are properly attached
before applying the test. Some items of plant may not be suitably
pressure rated and to avoid damage they must be temporarily protected
from over pressure for pre-commissioning work.
 Live utility systems may cause hazards to the uninitiated. When piping
is live it needs to be adequately identified. Certain personnel may need
to be trained to recognise these internal hazards.
 Isolation of equipment and systems is important for safe work on non–

commissioned process plant. To eliminate migration of construction or
pre-commissioning fluids into adjacent work envelopes, temporary
blinds, locked valves or disconnections are needed.
 Loss of integrity and containment has been known to result from

mistaken and unauthorised penetration of pipe or opening of flanges or
valves on a pressurised or finished system. Patrol of the work area is
important to avoid this. It is the function of the permit to work system to
address such risks, and at a certain time in the project execution it

becomes necessary to specify the exact workpiece when these
construction site risks are considered to exist.
 Certain activities eg. chemical cleaning or degreasing require the use of

corrosive fluids. Area controls and restrictions are required and should
be identified. Exact PPE and safety equipment should be specified.
 Unauthorised entry into construction site vessels is a construction site

risk which requires close management. Enclosed space breathing
environments can deteriorate without obvious indication. Personnel may
incapacitate themselves within enclosed spaces and remain
undiscovered. Internals can be damaged or their integrity compromised.
Secure temporary closure is required. Enclosed space entry is for
properly supervised and permitted work only.
 Mechanical and rotational checks require an evacuated work area.

Checks on the actions of remote actuators, motorised valves and other
mechanical devices need local inspection and attendance before the
workpiece is actuated from a remote location.
 The use of hoses should be subject to standard safety techniques and

training in their use. Example, hose condition and type is suitable for the
particular use. Crow's foot/bayonet connectors are secured/wired. Hose
is service tested at service pressure. The LP end of the hose
connection is open before opening the HP. The weight of the hose is
supported and restrained. Bonding or earthing connections are
available as required for flammable materials.
 The use of nitrogen, its containment, temperature, and venting control

can all introduce additional hazards to the construction site. Nitrogen
utilities will not be used at design distribution pressure before MC
unless fully safety watched.
 Control of connections to site sewers. Dissolved gases may be present

in water outfall sewer systems serving adjacent operating plant. The
situation needs careful review of the hazards when planning to connect
into drain and sewer systems serving operational areas.
 Hot surfaces, for example during testing of heat tracing, need to be

properly policed.
 Hydraulic shock may occur in flowing systems which could result in

sudden movement of piping. This causes a hazard to any personnel
C01 working close to piping which experiences this phenomenon. Therefore,
valves in large lines & pipelines through which liquid is flowing should
be opened or closed progressively to avoid hydraulic shock damage
(hammer).
 Radioactive sources. Statutory requirements must be complied with

before a radioactive source is used. NDT radiography areas should be
observed.
 Vessels designed with pressure containing nucleonic level devices may

require them to be fitted at tightness testing prior to MC. The source
shield must be in place or the source withdrawn by a qualified person
before any subsequent opening or entry is allowed.
 Electrical hazards will exist. A relatively early commissioning activities

will be to power up electrical distribution, control systems, building
supplies. Site standard electrical site safety rules, authorities and
responsibilities will apply from the outset of permanent energisation.
 High pressure nitrogen/helium tightness testing requires the evacuation

of all non-essential personnel from the test area and its surrounds. The
complete area will be barriered off with warning tape and signs posted.
6. SITE CONTROL OF PRE-COMMISSIONING HAZARDS

There are several elements of hazard control and management of risks which
will be used in combination to form a viable pre-commissioning risk management
program, as described below.
6.1 Planning and Procedures

Pre-commissioning work will be covered by detailed workplans and procedures.
Planning will be interfaced with area construction work and the sanction to
perform the work will be overseen by a single area authority.
Generic procedures and checklists will be employed for repeat activities. Parcels
of work will be described in a work pack and specific points for safe work and its
monitoring will be indicated on marked up PEFS and other job specific drawings.
Specific step by step method statements will be prepared for the safe control
activities such as HP tightness testing, ESD/EDP system tests, use of nitrogen
or chemicals.
6.2 Pre-commissioning Site Safety Induction

The CMC safety policies for the safety induction of site personnel are contained in
the Work Site HSE Plan. The site conduct during the pre-commissioning phase
will be covered in the site induction programme as follows:
All pre-commissioning personnel and construction personnel involved in pre-

commissioning will undergo a site induction consistent with the roles and
responsibilities and type of work being carried out.
Additional site training for the Contractors discipline personnel assigned to pre-
commissioning work will be given to emphasise the differences between
construction and pre-commissioning activities. To meet this requirement COMT
personnel will contribute and provide appropriate training material in conjunction
with site HSE personnel.
6.3 Safety Officers for Pre-commissioning

CMC construction site HSE Group will provide overall site HSE supervision and
policies for all project phases to MC. The Site HSE group will advise, assist and
support pre-commissioning activities and when required will provide additional
safety watch cover for activities that require high profile safety awareness to be
maintained. If required, the construction site HSE personnel will be
supplemented by personnel with plant pre-commissioning/operations experience
at the appropriate time as the site emphasis moves from erection to operational
testing.
Since much of the pre-commissioning work is likely to proceed alongside and/or

in close proximity to construction activities, consideration will always be given to
the potential for cumulative hazards to personnel as a result of these parallel
activities. When planning the work it is essential to ensure that possible interface
hazards are identified and appropriate segregation measures are anticipated
and implemented. This includes the requirements for safety officers, safety
watchers, gas testing personnel, and others who will have the single focus of
ensuring a safe working environment.
6.4 Job Specific Safety Briefings

Contractor and CMC site HSE personnel will convene and/or attend job site
safety briefings or “Toolbox Talks” for all personnel involved in pre-
commissioning work. These will generally occur at the start of the working day or
before commencing specific activities, to describe the team activities to be
carried out. They will be led by the supervisor in charge of the work. In addition
before the start of any pre-commissioning activity new to the team, the
supervisor will describe the upcoming work and how it should be implemented
and emphasise any specific safety procedures which may be applicable for that
task.
Routine weekly safety meetings will be held for pre-commissioning teams, and
led by the responsible CMC area pre-commissioning engineer. The safety
meetings will be used to highlight any significant upcoming activities and provide
two way feedback to the regular site-wide safety meetings.
Contractor supervisors will be required to hold regular team talks, in order to

explain details of area work plans and ensure the workforce understands all
safety related matters concerning the work, including advising others who could
be affected by these activities.
6.5 Notices and circulars

Pre-commissioning senior personnel will initiate circulars and notices to advise
all site personnel of the work to be carried out and the associated HSE
implications.
Site circulars will be issued to publicise relevant activities and inform of any site
constraints or safety control implications. These will be advised to pre-
commissioning and construction personnel for use in the job site safety briefings.
Safety Awareness notices will also be displayed on Site Notice boards.
6.6 Housekeeping
Good Housekeeping is a prerequisite of safe working with the objective of
accident prevention by reducing combustible materials to a minimum and
avoiding the creation of tripping hazards and obstructions in the working area.
Regular housekeeping will be performed throughout the working period. The

collection and removal of waste material will be handled through construction
site procedures
At the end of the working day, each area will be cleared of all rubbish and
maintenance materials and tools must be neatly stowed.
Loose materials etc. will be removed from platforms/railings where they could
create a tripping hazard or be knocked off causing a hazard to those working
below.
Access to ladders, stairways, emergency routes and fire escapes will be kept
clear at all times. Waste materials and refuse will be placed in properly
designated locations to prevent fire or tripping hazards.
The bulk of pre-commissioning work takes place in a construction environment

where much of the equipment is not yet installed in its final configuration.
Remaining temporary supports, temporary closures, temporary scaffolding,

handrails, walkways will feature in the prioritising of finishing work during pre-
commissioning, to provide safe phased systems for handover.
6.7 Pre-commissioning Safety Checklists

During the preparation and planning of any major pre-commissioning activity a
pre-commissioning safety checklist shall be completed by those who will
supervise the work. The checklist should be completed to address potential
hazards where kinetic operations involve significant flows, velocities, pressure or
temperature, or where chemicals or oils are used. The checklist will be
completed and retained by the pre-commissioning supervisor and used in
toolbox talks and to advise other personnel involved. The precautions raised by
consideration of the checklist items will be an input for any hazard assessments
required for work permit administration.
A Hazcon type hazard assessment may also be required where the activity
involves control of hazards which might have serious impact on adjacent
construction activities. Safety checklists and hazard assessments will also
involve CMC Site HSE personnel.
The example checklist below is to be implemented by the area pre-

commissioning engineer before any activities are performed involving air
blowing, rotating equipment operation, pressures in excess of 1 barg, use of bulk
nitrogen, hydrocarbons or chemicals
PRE-COMMISSIONING SAFETY CHECKLIST
PRE- COMMISSIONING / TEST ACTIVITY .................................................................
GENERIC/ SPECIFIC METHOD STATEMENT ..........................................................
PLANT ITEM ....................................................................................................
SYSTEM No. ........................................................................................................
LOCATION ........................................................................................................
Contractors involved / or affected by the work :-

Organisation/names
Item CHECKS TO BE CARRIED OUT YES NO INDICATE ACTUAL

PRECAUTIONS PRECAUTIONS
No OR ACTION CARRIED OUT
REQUIRED
(Tick as appropriate)
1. Are all interested parties aware of the
work? i.e. Shell witness / CMC
discipline / Contractors/ Vendor
Engineer(s)
2. Generic method statement with PEFS

markups
3. Specific Method Statement required,

reviewed, approved?
4. Is work in the local/adjacent area

required to be suspended, or
constrained, for the duration of the test/
pre-commissioning activity?
5. Specific requirements for “tool box” talks

with the work team?
6. Special requirement for PPE?
7. Have applicable MSDS sheets been

reviewed and made available?
8. Working boundaries to be defined and

barrier / signs to be placed.
9. Are supporting utilities available and

relevant personnel contacted?
10. Is the system isolated from other

REQUIRED
systems/ sections of plant by blinds,
physical disconnection or other means?
11. Have isolation valves / blinds within the

working boundaries been checked to
avoid contamination within the system?
12. Temporary installations e.g. temporary

supports, blinds, relief valves, piping
anchors for blowing etc. Site review and
requirements defined?
13. Is the area clear of all debris,

combustible material, construction tools
& equipment?
14. Are no-entry signs and road barriers

required? Is emergency access
adequate?
15. Is a written site notification to

construction or operations required for
control of adjacent activities?
16. Is area drainage adequate?
17. Is ventilation adequate? - requirements
18. Is the lighting adequate? - requirements
19. For work at height, confirm permanent

gratings and /or temporary scaffolding is
safe for use.
20. Are escape routes clearly defined/

understood?
21. Is any site presence / resource to be

organised from Safety/HSE Department
or Safety Watchers?
22. Is fire and gas system / firemain required
being operational. Are any special fire
precautions required?
23. Is job specific portable gas detection

equipment required?
24. Are open drain / effluent treatment units

REQUIRED
required to be isolated / in service?
25. Is temporary pressure relief valve

required?
26. Is flare/vent route required?
27. Specialised tools / equipment required?
28. Spill kits required if chemicals or oils to

be used?
29. Permits Type : HOT

COLD
ENTRY
ELECTRICAL
NOTES:
.......................................................................................................................
.......................................................................................................................
Above actions are in place and precautions reviewed with the team prior to implementation of
work.
PRE-COMMISSIONING ENGINEER
NAME: ..........................SIGNATURE............…… DATE...../....../.......
6.8 Permits To Work

During the pre-commissioning phase it is intended to continue to use the
Construction Permit to Work Procedure, according to document 011142-71-RP-
0004, for all greenfield site areas.
CMC pre-commissioning interface work with existing operating plant and with the
pre commissioning work will be covered by the normal Corrib operational permit
system.
CMC’s pre-commissioning work in the pig receiver, slug catcher and incinerator
areas will also be covered by the normal permit to work System.
6.9 Personal Protective Equipment (PPE)

This will be required as stipulated by standard site safety procedures. Where
unique measures are to be taken for specific pre-commissioning work, these will
be addressed in the method statement and reinforced through the safety
checklist and/or hazard assessment. PPE requirements and equipment will be
continually reviewed and policed by pre-commissioning supervision and site
HSE personnel.
6.10 Risk Assessment

As and where required by Corrib site procedures, work permit application will be
supported by a risk assessment of the hazards associated with the work.
This may take the form of a standardised document for repeat activities.
The hazard assessment and appropriate safety checklists will be reviewed at the
toolbox talk before commencing the activity.
A hazard assessment or a minuted hazcon may be required for pre-

commissioning work, according to the typical general approach as outlined
below:
Identify requirement for a specific method statement. This will normally be

required for multi-discipline activities or complex interface issues with other
contractors. This may be stipulated for high energy conditions, e.g. high
pressures, high volumetric flow, hazardous materials.
Breakdown the method or method statement into key sequential activities
Risk assessment involves rigid analysis of the existent hazards for each activity
by considering:
a. Hazards to Personnel (general public, adjacent operations, all site
personnel)
 Fire or ignition source
 Impacts or collisions
 Drowning, asphyxiation or electrocution
 Exposure to chemicals or gases other than atmospheric air
 Physical location of the work

a. Hazards to working environment
 Space requirements
 Claims on Water, Energy, Materials, Chemicals
 Access for others
 Site population density
 Sanitised area required
 Discharges to environment, Gaseous, Aqueous, Solid, Heat, Noise,

Light, and any cleanup/recovery measures that are required to be on
standby
 Safety watchers or gas testing demands
Assess severity of consequence - High, Medium, Low, None.
Assess probability of occurrence - High, Medium, Low, None.
Check if existing standard controls are adequate to cover risks - i.e. Permit
authorities, standard PPE, site warning signs & barriers, etc.
Is Risk acceptable with application of standard controls, Y or N?
Is acceptability subject to technical study or support? e.g. Calculations for

temporary works/ temporary loading/ specific safety margins, etc.
If more than standard controls required, identify specific additional method

statements that may be required to apply special precautions, technical advice,
materials, etc.
Investigate alternate if risk remains high
 Can the risk be avoided by changing sequence or timings?
 Is it possible to isolate or limit the work risk?
 Should working manning or resources be changed?
 Is there a different method to achieve the same result?
 More training, skills or equipment required?

C01
 More technical study/input required?
6.11 Supervision and Worksite Inspections

Prior to commencing work the following situations will be assessed:
 A stable footing or platforms (including railings) are in place for the

work.
 Suitable access and egress available.
 Undue presence of construction materials and scaffolding.
 Effects of nearby construction work and mobile plant.
 Lifting operations in vicinity
 Effects on access for others to continue their work
 Effects on nearby excavations
 Effects on adjacent operations
Throughout the period of the work being performed, the pre-commissioning

supervision will ensure the required safety measures are maintained. The control
and use of all lifting equipment and other mobile plant will be supervised under
the standard site rules and organisation applied throughout the construction
period.
6.12 Information to Others

Information on the work within the plant will be conveyed by visual/audible
means such as:
 Warning signs describing the hazard
 Barriers
 Specific coloured tapes
 Warning claxons.
 General announcement/ loud hailer
 Safety Tagging
 Presence of safety watchers
In addition notices will be posted at the normal entrance to the site or at the
permit control facility to provide information to all site personnel on the safety
significant pre-commissioning activities to be carried out that day, and any area
exclusions or limitations to be enforced.
6.13 Site Identification and Isolation of Live Systems

All live lines will be clearly identified and isolated as follows: -
 ‘Live’ sections of a line must be segregated from all other lines or

systems by positive isolation, with locked or chain locked closed block
valves and/or closed blinds.
 Process isolation blinds for systems shall be painted with a distinctive

C01 colour on their tabs or clearly labelled. See control of pre-
commissioning isolations.
 Warning signs will be attached to ‘live lines’ at intervals of not more than
5 metres and additionally identified with a special tape.
 Signs must denote state of line i.e. ‘HOT’, ‘UNDER AIR PRESSURE’
etc.
6.14 Electrical Safety.

Energising and Isolation of all equipment will be strictly controlled in accordance
with the Permit to Work Procedure and the site-specific Lockout and Tag-out
requirements for Electrical Equipment.
For detailed procedures and authorisation for energising/de-energising electrical

equipment refer to the standards in force at Corrib Project, i.e. Electrical safety
rules EA/082 and Electrical Safety Procedures ES/260.
The following general notes apply to electrical equipment.
Before switchgear is ready for energising access to electrical sub-stations will be

restricted to authorised personnel only and entry will be controlled.
Warning notices will be displayed whenever equipment is first energised or

under test e.g. "DANGER HIGH VOLTAGE - LIVE EQUIPMENT” or “MOTOR
ON TEST"
Motors under test will be closely supervised in order to prevent injury to

personnel. The area local to the motor under test will be identified with warning
tape and safety signs. Access/entry to this area will be restricted. Other work in
the local area, which is liable to interfere with the motor run will be suspended for
the duration of the test
When the motor solo run is in progress the authorised electrical person will
assign a qualified competent electrical person to monitor the duration of the
running.
All electrical motors not on test or in use will be electrically isolated and locked
off in the substation.
7. CONTROL OF SPECIFIC ACTIVITIES
7.1 Vessel and Confined Space Entry

No Pre-commissioning personnel or Contractor personnel working directly for
pre-commissioning will enter inside vessels or confined spaces without the
relevant permit authorisation being available at the work site. In addition no entry
will take place without an authorised standby person being in attendance outside
the vessel or confined space at all times.
Ensure there is a valid and recent gas test for the vessel internal logged in the
permit system.
On accepting permit conditions a brief inspection of the surrounding area by the

Pre-commissioning Engineer should be made:
 To confirm all isolation blinds are in place and no temporary hoses are
attached to vessel connections.
 To check that there is no vehicle exhausts or welding fumes liable to

enter the vessel while entry is in progress.
 To confirm the vessel or confined space is adequately ventilated and a

flow of air is present inside the vessel or confined space at all times
while entry is in progress.
 Ensuring adequate lighting is available inside vessel or have suitable

hand torches available and ready for use.
Entry inside vessel/confined space should be limited to a specified minimum and

maximum number of persons at any one time.
Minimise the number of loose items taken into the vessel. Prior to entry inside
vessel, ensure all items that can fall from pockets while inside are removed and
stored outside the vessel i.e. coins, pens, pocket-knives etc. Ensure flashlights
and other items are not left inside on exiting the vessel.
For large vessels and multiple work faces a tally system may be operated. Prior
to entering vessel/confined space, individuals entering the vessel should hand
over their identification tag to the standby man. This is to enable rapid head
count if required. On leaving the vessel/confined space the standby man will
return the ID tags.
Temporary and final vessel closures for pre-commissioning activities should be

witnessed by pre-commissioning personnel and the relevant vessel closure form
signed off. Final closure forms will be placed in the System Dossier. It will be
necessary to accurately confirm that no unwanted items have been left inside
the vessel on boxup and the pre-commissioning engineer should ensure that he
is the final person leaving the vessel.
7.2 Line Flushing and Blowing

On completion of successful hydrotest pre-commissioning personnel will prepare
to flush the section of piping which has been hydrotested. Air may be used to
assist in the flushing activity.
Permit Approval
Permits for the flushing and blowing will generally be issued as a continuation of
the hydrotest work.
Site Preparation
Where the line flushing is to take place, the area must be cordoned off and
warning signs “Line Flushing in Progress” placed in the surrounding area.
Drain facilities must be made available for the efficient disposal of water from the
area to the Open Drain system to prevent the area from flooding and possible
subsequent freeze over.
The surrounding area where the flushing is to take place must be prepared to
ensure that equipment within that area is adequately protected from water spray
and any debris that might be present inside the piping.
Before flushing is to take place the area must be thoroughly checked to ensure
that the water and eventually air is not going to interfere with any on going work
in that area or cause sudden distractions to the surrounding workforce.
Barriers and warning notices will be placed to control access to the flush exhaust
area. During the flushing of lines the area will be kept under observation by pre-
commissioning or the assigned Subcontractor until all flushing has been
completed.
During flushing and blowing of lines, the quantity of water drained down will not
be allowed to exceed the maximum run off water allowable by the Corrib Project
requirements. For high capacity flushing operations, pre-commissioning
personnel will liaise with SEPIL operations and environmental personnel on a
daily basis to ensure planned flushing work does not contribute any constraint to
Corrib Project operations.
7.3 Line Drying

When the cleanliness criteria has been achieved the line will be blown out and
dried out using dry air over an extended period until all moisture has been taken
up by the dry air. Care must be taken to when and where the air is to be vented,
it must be done in a strictly controlled manner so as not to distract or endanger
the surrounding work force or cause a long-term nuisance.
7.4 Low Pressure Air Tightness Test

Temporary pipe and hose fitting will be inspected to ensure there are no defects.
The temporary air hose will be secured at pipe-work interfaces to prevent
disconnection.
Where necessary on low pressure systems temporary pressure relief facilities

will be provide to atmosphere to prevent over pressurisation of equipment.
During the LP leak test, access to the area should be controlled and warning
signs posted.
Sections undergoing LP leak tests will remain under close supervision and will
be depressurised as soon as practicable after the test is complete.
At the end of the low-pressure leak test, the air will be de-pressured to
atmosphere, through drains/vents at safe locations.
The test envelope will remain boxed in under a slight positive pressure of dry oil
free air. This will serve as preservation until commissioning commences.
7.5 Assurance Air Blowing

Preparation for assurance air blowing of large piping runs is quite
comprehensive and requires detailed planning and site preparation to ensure
that the air blowing point is well caged in and secured in case of any foreign
objects remaining inside the pipe escaping and causing injury to the workforce.
This is achieved by preparing the area as follows:
The general area of the air discharge points will be taped off with Marker Tape,
approximately thirty meters from the blow out point.
The blow out point will be surrounded with scaffold barrier structure, and a
diffuser or muzzle fixed approximately one or two meters away from the open
end to restrain any solid projectiles. (Alternatively the blow out point must be
directed to a secured and evacuated location)
Where required piping will be restrained by use of “chain blocks” to restrict

movement.
Covering the whole barrier structure will be a tarpaulin securely fastened to the
scaffold frame. This will be a loosely lashed overlapped arrangement which will
assist in the containment of dust.
Suitable warning notices indicating "No Entry Air Blowing in Progress" or similar
will be positioned to cover all points of access.
Personnel not directly involved in the air blowing will be removed from the area
when the air horn is sounded.
All personnel in the noise-affected areas during the blowing activities will be
required to wear ear protection.
The blow out area will be checked thoroughly and patrolled to ensure that there
are no unauthorised personnel above ground or inside the Taped Off area. The
discharge area will be evacuated of all personnel well before the blowing is to
commence.
Air horns or alternative audible alarm will be sounded 5 minutes before the
intended air blow and again just prior to impending blowing
A specific permit to work and procedure will be required for assurance air
blowing of large systems.
Toolbox talks will be given as required to personnel involved in the work.
Efforts will be made to retain a contractor crew of regular team members to

assist in pre-commissioning activities. This will establish consistency of activity
approach in carrying out the work and the necessary safety control required
while carrying out the activities.
For details of the Generic Procedure for air blowing refer to the Plant and
C01 Equipment Generic Pre-commissioning Procedures.
7.6 Control of Blinds and Isolations

C01 These are covered by specific procedure
7.7 Introduction of Nitrogen

Certain piping systems may be preserved under a low positive pressure nitrogen
blanket during the pre-commissioning phase. Where nitrogen is used for
preservation, the equipment will be adequately labelled to indicate nitrogen
blanket. In some cases, positive isolations i.e. blinds or physical disconnection of
pipes will be used to segregate loaded drier beds under nitrogen blanket from
other sections of the plant.
Nitrogen distribution through the nitrogen distribution system will be maintained

at less than 1 bar. The term "Blanket" will indicate that only very low pressures
are utilised.
Before nitrogen is allowed on to the plant, CMC HSE will issue Safety Warning
Notices on site notice boards informing all personnel that nitrogen will be
introduced to the plant in the near future.
Process systems will generally be inerted by nitrogen purging after the

Mechanical Completion (MC) stage, in an operating environment, and in
preparation for admission of chemicals or hydrocarbons. Inerting will require the
nitrogen system to be in its normal service at its design operating pressure, and
in these circumstances the nitrogen system is considered to contain "high
pressure" nitrogen.
7.8 Guidelines for Nitrogen Purging General Safety Precautions

Nitrogen purging (inerting) involves the removal of oxygen from the process
plant to allow chemicals or hydrocarbons to be safely introduced into the plant.
Nitrogen purging is carried out under strict control and only when vessels and
equipment have been finally closed and permission has been obtained from the
pre-commissioning superintendent.
Prior to the introduction of pressurised nitrogen into any finished sections of

plant, the safety implications and requirements will be fully assessed and control
actions identified.
It should be noted that nitrogen is an asphyxiant and any activity involving

nitrogen purging in any construction area will be controlled by a specific permit to
work issued through the standard Corrib Project permit procedures.
For purging or inerting,
 Ensure any temporary hoses and fittings are in good condition and
rated for nitrogen pressure.
 Confirm availability of nitrogen supply for the anticipated volumetric

requirement for at least 3 purge cycle volumes.
 For a large volume pressure purge allow the system to stand at purge
pressure for a few minutes to allow mixing.
 Depressure the purge as rapidly as possible, taking into consideration

disposal route, safety and noise factors.
 Sample the purge for oxygen content after depressurisation to a slight

positive pressure of 0.1 or 0.2 barg.
 Repeat the pressure purge to obtain the desired oxygen concentration

at all sample points.
 Maintain under a slight positive pressure and retest for oxygen if the
subsequent start-up operations do not follow on immediately.
7.9 Precautions for High Pressure Nitrogen Tightness Testing
The hazards associated with high pressure compressible gas testing relate to
the release of the stored pressure energy and the consequence of high pressure
leaks. Note that all components will have previously been individually strength
tested prior to the HP tightness test. The HP N2/He tightness test concentrates
on the leak tightness and containment capability of the final and permanent
integration of these components.
Preparation:
Initial preparation for the system envelope to be tested will include reviewing and
identifying all flanges and confirming that no temporary gaskets or temporary
closures exist.
The test may include the combination of several adjacent systems provided that
the test/design pressure is consistent across the defined system limits.
The test envelope will be defined on the PEFS and a step by step procedure
developed.
Preparation prior to operational tightness testing, in particular for high pressure

systems, will include the following:
Barriers will be positioned around the area and warning signs “Do Not Enter
High Pressure Testing in Progress” will be positioned every fifteen meters
around the area.
Additional safety observers will be assigned to the area to ensure no
unauthorised persons enter inside the barrier while the test is in progress.
Pre test inspection:
 System relief valves are in service
 System blow down valves are in service
 Special bolt tensioning complete
 Locked open/locked closed valves are in the correct position in

accordance with PEFS
 System blinds are in the correct operational position in accordance with

PEFS
 General checkout of system physical status and appearance
 Isolations for the test envelope will be determined and the envelope
defined on a marked up PEFS
 Test pressure should not be allowed to approach relief valve set

pressure, and the maximum pressure should be specified accordingly -
typically 95% of RV set pressure.
 Suitably calibrated/tested pressure gauges in use.
 The tests will normally be carried out against normal process isolation
valves rather than temporary blinds.
 The test sequence will be planned and defined such that permanent
flanges are not to be disturbed after the test.
 The leak tightness of any closed valves forming the limits of the
envelope will be confirmed by monitoring the pressure frequently in any
downstream equipment.
 Suitable vents will be opened where required in order to prevent over

pressurisation in downstream equipment.
 Any isolation blinds used will be rated for line pressure rating and test
pressure.
During the test, access to the area will be restricted by placing barrier tape
completely around the test area. Warning signs will be posted every 15 meters.
Safety observers will patrol the area to enforce the restrictions in force.
On completion of the test the pressure should be released in a controlled

manner and to a safe location.
On completion of depressurisation the barrier tape and warning signs will be

removed and the area opened for access.

Precommissioning General Safety

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Shell E & P Ireland Ltd

Corrib Project Onshore Gas Terminal CMC

Pre-Commissioning General Safety Procedures

File No. 011142.71.510 CMC Document No: 011142-71-PR-0015

PREVIOUS ISSUES (Type Names)

6. SITE CONTROL OF PRE-COMMISSIONING HAZARDS 10

7. CONTROL OF SPECIFIC ACTIVITIES 19

7.7 Introduction of Nitrogen 22

The document also contains information and guidelines on permit to work

The overall objective of this procedure is to develop a consistent understanding

Where work is carried out at Contractor prefabrication sites, or where work is

These precommissioning safety measures do not intend to give detailed or rigid

Permit to Work Procedure

Generic Pre-commissioning Procedures and equipment

Control of Pre-commissioning Isolations

Electrical Safety Rules EA-082

4.1 Construction Manager

4.2 HSE Manager

4.3 Pre-Commissioning Superintendent

5.1 General Conduct of Work

Pre-commissioning work is the essential bridge activity between material

Pre-commissioning hazards incorporate all of those hazards normally managed

The pre-commissioning workscope on the Corrib Project Onshore Gas Terminal

 Punchlisting against specification for Mechanical Completion

 Review of installed facilities for safe operability and maintainability

 Ensuring plant integrity for subsequent commissioning scope

 Planning system and area MC completions for effective commissioning

 Flushing and cleaning using water or air

 Energised testing of Electrical Distribution

 Inspection of plant internals for serviceability

 Loading certain chemicals, molecular sieves and other inventories

 Equipment Inspections for serviceability

 Preparation of rotating equipment and ancillaries

 Local use of chemicals, nitrogen, flushing oils, lubricating oils

 Use of temporary equipment and construction plant

 Control of isolations for safety and conservation

 Use of flow, pressure and temperature

 Air blowing through process vessels and piping

 Alignment and leak testing

 Chemical cleaning (if required)

 Use of normal utility water and air supplies

 Testing of instrument items for functionality

 Uncoupled running of equipment drivers

 Tightness and containment testing

 Control and ESD System interface functionality

The above work focuses on preparing operational configurations of the facilities,

Pre-commissioning excludes the following categories of work, which will take

 Process flowing of HP nitrogen

 Running of major rotating equipment

 Circulation of liquids or gases using permanent pumps, compressors.

 General purging and gas freeing of plant

 Introduction of bulk hydrocarbons for testing

 Introduction of normal process chemical inventory or normal feedstocks.

5.2 Safe Conduct of Specific Types of Work

 Work on unfinished plant. Most pre-commissioning work on piping and

 Sudden or continuous noise may be generated by pre-commissioning

and personnel protection issues. Where a high level of pre-

 Release of pressure. This may be from a much larger enclosed volume

 Falling objects. Pre-commissioning work can set up vibrations. Checks