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HYDROGEN GENERATION UNIT (EPCC-06

PROJECT : PACKAGE) FOR VISAKH REFINERY
The present document or drawing is property of TECHNIPFMC ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed

MODERNISATION PROJECT, HPCL

LOCATION : HPCL VISAKHAPATNAM, ANDHRA PRADESH

OWNER PMC LEPCC

DOCUMENT NAME
SITE SIMOPS MANAGEMENT PLAN
CONSTRUCTION, COM & PRE-COM

Document Category Document Review Status (by Owner / PMC)

1 Approved / Reviewed
Approval
2 Approved / Reviewed with comments as marked
Review
3 Not Approved / Resubmit
Information
4 Retained for Information / Records

Date: Name:
This approval does not absolve the Contractor from meeting their contractual obligations
of delivering a complete, safe and efficiently operating units/facilities meeting all
requirements of the contract.

Pages modified under this revision:

naprasad@t Digitally signed by

[email protected] Ashish Dwivedi
echnip.com 2018.12.12
DN: [email protected]
Date: 2018.12.11 14:18:43 +05'30'

18:28:01 +05'30'

0 12.11.2018 ISSUED FOR APPROVAL N.T.PRASAD ASHISH.D/MARCO.S I.S.RAO

Date
Rev STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MM/YYYY

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the margin
upon right of use.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.

CONFIDENTIAL – Not to disclose without authorization

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INDEX

1. SCOPE AND OBJECTIVES .........................................................................................................................

2. ABBREVIATIONS ........................................................................................................................................
3. WORKING HOURS AND MAN POWER ......................................................................................................
4. ROLES & RESPONSIBILITIES ....................................................................................................................
5. TRAINING ....................................................................................................................................................
6. PRESENT SAFE GUARDS .........................................................................................................................
7. ATTACHMENTS ..........................................................................................................................................

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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SITE SIMOPS MANAGEMENT PLAN

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which

1. SCOPE AND OBJECTIVES

This SIMOPS Management Program (SMP) is prepared to provide effective solutions for safe
work execution by handling any situation during any gas leak or any type of emergency due
to existing facilities during the construction, pre-commissioning, commissioning including all
activities till the Ready for Initial Start-Up.

Hereafter OWNER termed as HPCL VRL, EIL (Project Management Team) as EIL Technip
FMC is termed as CONTRACTOR, Sub-Contractors who are working under CONTRACTOR
for construction activity in this project.

The present Site HSE Plan & Site Emergency Response Plan, risk register applies to topics
covered by OWNER/EIL regulations the HSE prescriptions that may be more restrictive to
control the losses, will be applied. In addition to this CONTRACTOR HSE management
systems will also be implemented to achieve safe work execution in the site.

SCOPE OF WORK

The scope of work for CONTRACTOR on Licence, engineering, procurement, construction

& commissioning (LEPCC) including mobilisation of Licensing/Licenser. The scope of work
shall include Project Management, Licensing, preparation of BDEP including Residual
Process Design engineering, Detailed Engineering (including HAZOP and SIL study, Risk
study), procurement, fabrication, inspection, transportation of all the equipment and materials
to work site, storage, assembly, erection, installation, process and utilities hook up to the
existing refinery network, construction and testing, including statutory approvals, and to
achieve mechanical completion, pre-commissioning, commissioning, performance
guarantee test run (PGTR) and handing over of all the facilities to Owner including transfer
of license, supply of mandatory / recommended spares based on bid document and also first
fill of chemicals, catalyst and lubricants for EPCC – 6 Package.

LANGUAGE
it is specifically furnished or outside the extent of the agreed upon right of use.

The project language will be English and HINDI as a National language, multilingual
communication shall be foreseen including local language TELUGU for the basic
understanding of major HSE aspects, rules, regulation and practices. The key roles of each
organization at Site, till the Foremen, shall be able to communicate in English language.
However, the organization on site shall provide any suitable means, in order to overcome
language barriers, if any.

REFERENCE:
Project HSE Plan : 077015C-00-PP-512
Emergency Response Plan : 077015C-00-PP-808
SAFE WORK PRACTICES : GGL-OOS-22001
SITE HSES OPERATING SYSTEM : GPS-OOS-22010
OWNER/EIL JOB SPECIFICATIONS : B016-6-82-0001 Rev.0

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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HPCL VRL HSE MANUAL : Rev.04. 2015

HAZOP & Risk Register :

2. ABBREVIATIONS

The abbreviations listed, when used in this Waste Management Program (WMP), shall
have the meanings ascribed here below:

OWNER HPCL, VIZAG

EIL ENGINEERS INDIA LIMITED (EIL)
CONTRACTOR TechnipFMC
SUBCONTRACTOR Means the party with whom contractual relationship are
formed by TechnipFMC
HSE Health, Safety and Environment
JHA Job Hazard Analysis
LOTO Lock-out & Tag-out
ODS Ozone Depleting Substances
OEL Occupational Exposure Limit
OSHA Occupational Safety & Health Act
PC&C Pre-Commissioning &Commissioning
PCC&SU Pre-Commissioning, Commissioning & Start Up
PPE Personal Protective Equipment
PSSR Pre-Start-up Safety Review
PTW Permit to Work (Hot, Cold, Confined Spaces, NDT, etc.)
SCBA Self-Contained Breathing Apparatus
SEW Safe Execution of Work
VOC Volatile Organic Compound
PRE-COM Pre-commissioning
COM Commissioning
SIMOPS Simultaneous Operations
VRMP GI VRMP General Instruction
HSE Health, Safety and Environment
LPP Loss Prevention Program (Site HSE Plan)
VRMPCSM VRMP Construction Safety Manual
VRMPES VRMP Engineering Standards
ESIA Environmental and Social Impact Assessment
ESMP Environmental and Social Master Plan
Project ESMP Project Environmental and Social Management Plan

3. WORKING HOURS AND MANPOWER

CONTRACTOR and the SUB CONTRACTOR working hours and manpower shall be
estimated in accordance with the specific scope of work and will be detailed in the specific
Contractor Execution Plans. Work outside the official work hours and working on public
holidays, Sundays will only be allowed in special circumstances and requires specific
This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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authorization by the CONTRACTOR Site Manager and prior approvals from the OWNER /
EIL Site Representative. All work of this type will need to have a specific plan to address the
hazards (e.g.: proper technical supervision, adequate lighting, emergency and safety
surveillance, etc.) that this type of work might require. This is to ensure all times monitoring
of these workers who are working in sub-station and East side of HGU plot areas.

The normal manpower load during the civil phase shall be of about 450 direct peoples, during
the mechanical erection phase shall be of about 1500 direct persons and during the
electrical/instrumentation phase shall be of about 470 direct peoples; indirect people in
performing the works shall be of about 400 indirect peoples.

4.0 PURPOSE & METHODOLOGY

This document applies to all activities undertaken by CONTRACTOR and its

SUBCONTRACTORS on the of HGU project EPCC 06 for HPCL, Refinery, VIZAG A.P India
and shall apply to all persons accessing the site. Any deviation from OWNER / EIL safety,
health and/or environmental requirements must be discussed and agreed with
CONTRACTOR and approved in advance and in writing by the OWNER/ EIL Project HSE
Manager.

Main purpose of this document to ensure safe work execution in HGU plot and substation &
SRR area with simultaneous operation of existing SRU unit and CPP units which are located
on either side of EPCC 6 project sites.

This document describes further on preventive measures initiated by CONTRACTOR at HGU

plot, sus-station & SRR unit areas. This procedure shows type and number of gas detectors
along with alarm system (audible & Visual) on/near barricading which will be second level of
warning. CLIENT fixed gas monitors in existing SRU unit will give alarm in case of any gas
leak. This is in addition to the basic precautions to be taken when working in these areas.
Detailed flow chart if prepared for clear description later in this procedure. This procedure
was prepared basing on the data provided by CLIENT. CLIENT GAS monitors will give 1st
alarm @ 10PPM and 2nd Alarm @ 20PPM. Fixed gas monitors and H2S personal monitors
will give alarm @ 5PPM, this is to give more redundancy in alerting the person who are
working in that areas.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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Moreover, HAZOP, Risk Management study & EIA requirements for SIMOPS Management
Plan requirements will be applied.

This SIMOPS Management Plan shall be applied by CONTRACTOR, together with its
Subcontractor(s), Suppliers and Vendors present at Site, performing Construction, Pre-
commissioning and Commissioning works, till Ready to Start-up activities.

Should anything be missed in this Program, CONTRACTOR shall refer to the above-
mentioned Laws, Regulations, Contract obligations, etc. This Program may be reviewed
and updated whenever necessary or from one phase to another one of Site activities.

OWNER Representative may provide assistance to the CONTRACTOR by providing all

required information regarding existing units (gas detecting systems, calibration
certificates, drill reports, notification of any un towards incidents, accidents, lessons learned
etc., which will enable CONTRACTOR to further provide necessary communication to its
sub-contractors work men during any unexpected events. Such assistance by OWNER
shall in no way relieve CONTRACTOR and Subcontractor(s) of their own responsibilities.

CONTRCATOR to ensure proper tools box talks and communication by visual and during
trainings on site emergency response plan and shall ensure conduct regular drills to ensure
compliance.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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5. ROLES AND RESPONSIBILITIES

The general HSE roles and responsibilities are set out in the Project HSE Plan, what is stated the
Site HSE Plan, each Subcontractor shall follow site HSE organization and responsibilities.

➢ CONTRACTOR is responsible for the implementation of this SIMOPS Management Program

by its own and Subcontractor(s) during its scope of site activities with inputs provided by
CLIENT.
➢ Subcontractor(s) is responsible towards CONTRACTOR for implementation and compliance
of all its employees with this SIMOPS Management Program.

➢ Site Organization remains first responsible to implement the stipulated guidelines.

5.1 Site Management

CONTRACTOR, through the Site Management, is responsible for site compliance with and the
implementation of SIMOPS Management Plan for ensuring that Subcontractor(s) comply with the
requirements set out within this plan.

In particular Site Management is responsible for:

➢ Approval of the final SIMOPS Management Plan.

➢ Ensure that the responsibilities of all employees are clearly defined and that all employees,
contractors and sub-contractors are aware of their responsibilities and are adequately trained
and motivated to carry them out;
➢ Ensure that budgeting plans make available resources required for effective implementation of
the SIMOPS Management Plan.

5.2 Site HSE Manager

The CONTRACTOR Site HSE Manager is responsible for the implementation of HSE procedures
and regulation at site and will focus on ensuring that the CONTRACTOR HSE Team,
Subcontractor(s) and all site workers operate systems of work compliant with the CONTRACTOR.

• Ensuring that CONTRACTOR and all Subcontractor personnel are trained and aware of site
emergency procedure.
• Ensuring regular inspections and gas monitoring is being carried out before start of work.
• Ensuring all staff has been given adequate awareness training to enable them to carry out their
duties in a manner that will enable compliance with this procedure.
• Responding to any emergencies and proper coordination with CLIENT concerned persons.

5.3 Subcontractors

• Subcontractors MUST COMPLY with the requirements set out in this Program.
• Subcontractors SHALL ESTABLISH a similar chain of accountabilities and responsibilities to
those set out above for HSE matters within their own organization(s).

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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SITE SIMOPS MANAGEMENT PLAN

5.4 All Project Site Employees

The workforce has a “Duty of Care” to respond in line with the plan and have the following
responsibilities. Co-operate with all responsible persons to ensure the effective implementation of
the SMP.

6.0 TRAINING

Training on site SIMOPS Management Plan with respect to H2S danger to all persons who are
working in sub-station and East side of HGU site.

All employees shall be instructed prior to start of work and subsequently during toolbox meetings
to communicate. Information will be provided on use of these personal monitors and fixed gas
detection system.

Drivers shall be instructed on risk control measures to be followed, and what to do in case of
emergency.

7.0 PRESENT SAFE GUARDS TO BE FOLLOWED

• Training to all workmen who are working in sub-station area on H2S.

• Main work supervisors and HSE are being issued with personal H2S monitors.
• Frequent communication to all during mass tool box on actions to be taken during
any emergency.
This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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• Provision of fixed gas detectors along with hooters and flashing lights at different
locations.
• Detailed inputs on Actions required during any emergency during initial HSE
induction.
• Regular daily shift wise GAS monitoring in all work sites before start of work.
• Obtain drill reports from CLIENT on regular basis.
• Obtain existing plant gas detectors calibration reports from client.
• Regular tool box talks on H2S and other emergency situations and actions to be
taken.
• Display of warning signs and emergency contact numbers and regular update during
daily tool box talks.
• Ensure HSE and execution coverage 24x7.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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Personal H2S Monitors

8 ATTACHMENTS

Overall Plot Plan

On-site Mock drill report pertaining to SRU Unit -A
Gas Detectors Calibration Report DSRU -B
Gas Detectors Calibration Report DHDS -C

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization