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Work Authorization

Process safety & Asset integrity

Management system

Reference to (Continuous Service Agreement) signed by and between Suez Oil Processing Co.
(xxx) as First Party and EPROM as Second Party; this Work Authorization had been signed by and
between Parties representative to enter into force on its date and according to the following data,
terms and conditions.
CSA BY AND BETWEEN SOPC & EPROM
CSA /TSA DATED : XX/XX/2021
W.A SERIAL No.: WA-CLIENT-…..-2021
W.A DATE: DD/MM/YYYY
W.A TOTAL AMOUNT :
Work Authorization Content includes but is not limited to the following;
1. INTRODUCTION 
2. SCOPE OF WORK 
3. EPROM RESPONSIBILITIES 
4. SOPC RESPONSIBILITIES 
5. WORK LOCATION 
6. PROJECT DURATION 
7. PRICING AND TERMS OF PAYMENT 
8. ATTACHEMENTS ☐
Rates apply as one of the following check ( ) for right box;
Daily Rate: ☐ Lump sum :  Unit Rate: ☐
TERMS AND CONDITIONS OF THE W.A:
1. All terms and conditions of the (CSA) are applicable and in force between the parties.
2. In case of conflict between the provisions of this Work Authorization and the original Agreement,
the provisions of the Work Authorization shall prevail.
CLIENT PROJECT MANAGER EPROM PROJECT MANAGER
NAME: NAME:
SIGNATURE: SIGNATURE:

DATE: DATE:
CLIENT CONTRACTS MANAGER EPROM CONTRACTS MANAGER
NAME: NAME:
SIGNATURE: SIGNATURE:

DATE: DATE:
CHAIRMEN APPROVALS
ON BEHALF OF CLIENT ON BEHALF OF EPROM
NAME: NAME:
SIGNATURE: SIGNATURE:

DATE: DATE:

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1- INTRODUCTION
This work authorization is drafted in connection to the governing CSA, where EPROM
provides the qualified experts and necessary technical support for SOPC, SOPC intends to
apply a process safety & asset integrity management system (PSAIM).

The approach presented here is to develop an appropriate process safety management (PSM)
system based on the CCPS Risk-Based model (20 element).
An RBPS management system incorporates four main accident prevention pillars
(foundational blocks) – as shown in fig. below:

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2- APPROACH

Risk Based Process Safety is the latest approach published by CCPS, the RBPS recognizes
that all hazards and risks in all facilities are not equal; A risk-based approach reduces the
potential for assigning an undue amount of resources to managing lower-risk activities,
thereby focusing the available resources for tasks that address higher-risk activities.

1st pillar: Commit to Process Safety (5 elements)

Management commitment has no substitute, this pillar includes five main elements –
1- Process Safety Culture
2- Compliance with Standards
3- Process Safety Competency
4- Workforce Involvement
5- Stakeholder Outreach
 Developing and sustaining a culture that embraces process safety.
 Identifying, understanding, and complying with codes, standards, regulations, and laws.
 Establishing and continually enhancing organizational competence.
 Soliciting input from and consulting with all stakeholders, including employees, contractors,
and neighbors.

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2nd pillar: Understand Hazards & risk (2 elements)

In order to be able to allocate the limited resources in the most effective manner, SOPC shall
firstly understand the hazards and risks associated with the processes with which the workers
will interact. This pillar includes two main elements:
1- Process Knowledge Management
2- Hazard Identification and Risk analysis
Understanding the risk can be achieved through focusing on:
 Collecting, documenting, and maintaining process safety knowledge.
 Conducting hazard identification and risk analysis studies.

3rd pillar: Manage Risk (9 elements)

Managing risk helps company or a facility deploy management systems that help sustain long-
term incident-free, and profitable operations. This pillar includes 9 elements:
1- Operating Procedures
2- Safe Work Practices
3- Asset Integrity and Reliability
4- Contractor Management
5- Training and Performance Assurance
6- Management of Change
7- Operational Readiness
8- Conduct of Operations
9- Emergency Management
 Developing written operating procedures that provide written instructions that operators can
execute when they encounter process upsets/unsafe conditions.
 Implementing an integrated suite of safe work policies, procedures, permits, and practices
to control maintenance and other no routine work.

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 Executing work activities to ensure that equipment is fabricated and installed in accordance
with specifications, and that it remains fit for service over its entire life cycle.
 Managing contractors, and evaluating work performed by contractors, to ensure that the
associated risks are acceptable; ensuring that contractors are not exposed to unrecognized
hazards or undertake activities that present unknown or intolerable risk.
 Providing training and conducting related activities to ensure reliable human performance at
all levels of the organization.
 Recognizing and managing changes.
 Ensuring that units, and the people who operate them, are properly prepared for start-ups.
 Maintaining a very high level of human performance, particularly among operators,
maintenance personnel, and others whose actions directly affect process safety.
 Preparing for and managing emergencies.

4th Pillar: Learn from Experience (4 elements)

SOPC shall develop a culture and infrastructure that helps them learning from the lessons and
apply them in the future. Metrics can be used to provide timely feedback on the workings of
RBPS management systems, and management review, a periodic honest self-evaluation,
helps sustain existing performance and drive improvement in areas deemed important by
management.
This pillar includes 4 elements:
1- Incident Investigation
2- Measurement and Metrics
3- Auditing
4- Management Review and Continuous Improvement
 Investigating incidents that occur at the facility to identify and address the root causes.
 Applying lessons from incidents that occur at other facilities within the company and within
the industry.
 Measuring performance and striving to continuously improve in areas that have been
determined to be risk significant.

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 Auditing RBPS management systems as well as the performance of work activities that
make up the management system.
 Holding periodic management reviews to determine if the management systems are
working as intended and if the work activities are helping the facility effectively manage risk.

3- SCOPE OF WORK
SOPC assigned EPROM to establish the PSM to the SOPC units inside refinery battery limits as
shown in below-
1- Asphalt unit (U-33)
2- CDU-1
3- CDU-2
4- CDU-3
5- VDU
6- U-20 (Reformer complex)
7- U-21 (Reformer complex)
8- U-22 (Reformer complex)
9- Utilities Units
10- Hydrogen plant
11- Tank farm, pump houses, loading & Unloading Platform
12- Offshore SOPC platform (Process safety studies only)

4- DETAILED SCOPE OF WORK

The PSM project will be executed on three phases:

 Phase 1:
1- GAP Analysis & review the results against the EGPC PSAIM report.
2- Awareness & training.
 Phase 2:
1- Developing the system (policies, strategies, procedure, guidelines ..etc) in dual
language ( Arabic & English) , which comply with EGPC guidelines & procedures .

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2- Providing the technical Support / Assistance required for system implementation.

3- Monitor system & KPIs shall be included to each element.
4- Training.

 Phase 3:
1- Conduct the required PSM/AIM studies and Revalidating the outdated studies
2- PSM/AIM studies for asphalt unit to be done if needed .
3- Review & audit on the system output as per CCPS RBPS .

4.1 Methodology & Deliverables:

Element 1: Process Safety Culture
 Develop an effective communications Matrix for All levels.
 Establish a questionnaire For Culture Assessment.
 Policy & strategy rollout across the company, DISTRIBUTION & Awareness, and
develop a vision statement for process safety culture.
 Providing PSM KPIs Dashboard
 Establish a formal Management Walkthrough program to cover all SOPC location
 Establish a digital monthly process safety newsletter to go to all staff. Covering PSM
progress in the refinery, incidents and the learnt lessons.
 Process safety culture review & Evaluation.

Element 2: Compliance with Standard

 Conduct compliance assurance process.
 Establish a written procedure for applicable codes & standards identification.
 List & update all codes, standards, regulations, and laws required to comply with.
 Providing the required codes, standards as determined in clause 10.0

Element 3: Process Safety Competency

 Develop Competency Matrix for all PSM/AIM system personnel.
 Establish specific criteria for Competency assessment

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 Certified training for EX equipment maintenance (for 5 personnel).

 Providing training of operations personnel on safe operating as per clause 10.0

Element 4: Workforce Involvement

 Develop a procedure for Workforce Involvement of all job levels.
 Owners

Element 5: Stakeholder Outreach

 Establishing a procedure to determine the concerned parties (Internal / External).
 Identify Communication and Outreach Needs.
 Defining the methods and the system for communicating with the concerned parties
(Internal & External communication procedure).
 Devolving a process for Appointment of SOPC representatives & Speakers In case of
Incidents and their Responsibilities.
 Identify the types of information and messages that should be communicated for each
stakeholder group.

Element 6: Process Knowledge Management

 Establish procedure for identifying, developing & maintaining the required documents to
support the operation and maintenance of the facilities
 Provide MSDS for the hydrocarbons such as Kerosene, gasoline etc.
 Develop a database for Process Safety Knowledge Management.
 Gathering / assembly the Process knowledge data & information.
 Conduct data base of written information process chemical, process technology &
process equipment.
 Confirmation that this information must be readily available to those who need it to
safely perform their jobs.
 Updating process description.
 Providing Process chemical & dangerous substances inventories.
 Providing safety equipment layout

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 Establish a system to properly protect documents and records, including those that are
archived electronically.

Element 7: Hazard Identification and Risk Analysis

 Prepare & Establish SOPC Risk management guideline.
o Develop Risk management Policy & Strategy.
o Prepare PHAs procedures.
o Develop the risk assessment procedure, preparing the risk matrix and the
company's risk acceptance criteria.
o Establish Hazards & Risks Register
o Establishing a procedure for recommendations tracking & completion of actions.
o Set system for Communicate results internally, externally & Maintain risk
assessment records.
 Conduct Risk analysis workshop using Bowtie tool.
 Conduct HIRA studies for the existing facility and review the old studies.
 Provide training to the participating team for the safety studies methodology.
 The PHA & safety studies leader to be assigned after agreement between both SOPC
& EPROM

Element 8: SOPs Operating Procedures

 Developing operating procedures for all operation units, Tank farm areas and Utilities
Using an appropriate format.
- State the Safe Operating Limits (SOL); as well as the steps required to prevent
diffraction outside of SOL and address the consequences of deviation from safe
operating limits.
- Procedures will include different operating modes.

- Ensure that the procedures describe the expected system response, how to
determine if a step or task has been done properly, and possible consequences
associated with errors or omissions.
- Supplement procedures with checklists.

- Develop written procedures to control temporary or non-routine operations.

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- Validate procedures and verify that the responsible person understands their rule.
 Providing Interlink related procedures.
 The guidance shall also include:
- Developing the Responsibility and Accountability matrix for reviewing and
updating all Operating
- Review and update all detailed process description, ensure that it is in place and
the key operational areas are identified.

Element 9: Safe Work Practices

 Establish a written Safe Work Practices policy.
 Develop safe work procedures, instructions, permits, checklists, and other written
standards.
 Review approved practices to take into account changes in legislation and standards.
 Designate the authority to approve practices.
 Setting a policy for controlling access to particularly hazardous areas & Access control
procedures.
 Establish Audit system for completed permits, to improve safe work practices.

Element 10: Asset Integrity

 Provide RBI study to the static equipment as mentioned in clause 5.0
 Deployment of an RBI software as mentioned in clause 5.0
 Provide RCM study to the rotating equipment as mentioned in clause 6.0
 Providing a quality assurance program.

Element 11: Contractor Management

 Establish a procedure for contractor management (Pre-qualification, planning,
evaluation,...etc. ) As required and with according to EGPC guideline and related
formula.
 Evaluating contractors:
- Establish procedures for evaluating contractors and suppliers.

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- Define the criteria for evaluating the performance of contractors and suppliers.

- Establish a monitoring and follow-up system during the execution of the works.
 Setting the procedure of communication to contractors and suppliers of work
requirements and services.
 Developing contractor site orientation plan.
Element 12: Training and Performance Assurance
 Setting training Matrix and Identify training needs for all SOPC Staff through a
systematic process.
 Conduct a job/task analysis; determine minimum requirements (or essential elements)
for job candidates.
 Establishing systematic and effective training and development programs to ensure
that each person is qualified to understand, accept, and assume the responsibilities of
process safety identified for their role.
 Officially review & evaluate training and development programs to assess their
effectiveness and identify opportunities for improvement.
 Setting up a system for obtaining training programs eligible for promotion and
preparing a testing and evaluation system for job vacancies, in accordance with the
requirements of the General Petroleum Corporation.
 Setting up an evaluation system for companies and contracting parties to provide
training services, including evaluation of scientific materials and the competence and
experience of the lecturer / training audit and assessments and periodic review of all
programs.
 Identify & address cause of poor performance and implement corrective.

Element 13: Management of Change

 Identify the scope of the MOC system, manage all sources of change, and evaluate
possible impacts.
 Develop a step-by-step change process management procedure .
 Training employees to apply change procedures.
 Identify a site MOC coordinator & related responsibilities.

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Element 14: Operational Readiness (Pre-Startup Safety Review PSSR)

 Establish a systematic process, procedure & related Checklist to verify the operational
readiness and integrity of the systems before they are put into service.
 Develop a Procedure for ensuring that shut down processes are verified to be in a safe
condition for re-start.

Element 15: Conduct of Operation

 Development of Conduct of Operations Guidelines.
 Set system to ensure that performed tasks are done exactly as prescribed over a long
period of time.
 Developing Procedures for managing overlapping operations.
 Developing Access control procedure.
 Providing Shift to shift turnover procedures.
 Providing Housekeeping program.

Element 16: Emergency Management

 Reviewing The Existing emergency procedures for all identified emergency scenarios
including those related to adjacent facilities and areas.
 Update the emergency plan with the participation of workers’ representatives from all
relevant departments.
 Provide written or electronic copies of the plan in different workplaces.
 Developing a procedure for calling out emergency response Control Centre.
 Establish a plan for mock & tabletop drills that includes the participation of all relevant
departments and on all potential scenarios and levels covered by the emergency plan.
 Develop a training plan on the emergency response plan (ERP) for all employees who
have responsibilities in activating the ERP.
 Conduct table top drills.

Element 17: Incident Investigation

 Define an appropriate scope for the incident investigation element.
 Develop accident investigation procedures & related documents according to the level
of the accident.

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 Determine the methods used in the accident analysis process.

 Providing system for STOP & Near-miss Reporting.
 Providing reward & incentive program (to motivate workers to report safety and process
risks and employee participation in developing solutions).
 Developing a system for recording accidents.
 Identifying Incident Investigation team.

Element 18: Measurement and Metrics

 Develop PSM Metrics procedure.
 Develop PSM Key Performance Indicators “Lead& Lag “
 Develop Metrics tracking procedure to identify corrective actions & drive improvement.
 Provide training on PSM Metrics for all Focal persons.

Element 19: Auditing

 Providing a routine audit program that reviews and assesses compliance with PSM
requirements and determines audit activities and arrangements.
 Develop process safety audit methods.
 Identify qualified Audit team and their responsibility.

Element 20: Management Review &Continuous Improve

 Establish procedures for Management review SOPC’s operations & monitoring, the
process safety management performance, and to regularly reviewed by specific levels
of senior management.
 Develop a documented management review program:
- Review compliance and performance trends for all elements by the SOPC top
management with Conduct field inspections.
- Review the effectiveness of the audit arrangements periodically and use the results
to make continuous improvements.
- Evaluate results from management reviews and proposed/reviewed
recommendations for improvement.

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- Engage management to follow up and close out actions derived from management
reviews.

4.2 Responsibility Matrix

 The responsibility matrix of the project is as below –

Abbreviation
R I C
Responsible Informed Consulted

Responsibility Matrix EPROM SOPC Remarks

1- Process safety culture
Phase 1
Process Safety Management Course (1 Week) R I To SOPC focal
persons
Phase 2
One Day training session about PSM policy & strategy R I To SOPC focal
persons
Presentation of the PSM policy and strategy to system R I
Owners
Development of PSM policy & strategy & One Day R I
training session about PSM policy & strategy
Review & approval of PSM policy & strategy (Limited to C R
Draft & Final version)
Policy & strategy rollout across the company C R
Phase 3
Process safety culture review R I
2- Compliance with standards
Phase 2
One Day training session about Compliance with R I To SOPC focal
Standards Guideline persons
Presentation of the Compliance with Standards R I
Guideline to system Owners
Development Compliance with Standards Guideline R I
Review & approval of Compliance with Standards C R
Guideline (Limited to Draft & Final version)
Compliance with Standards Guideline rollout across the C R
company (including Standards Register & Access to
standards)
3- Process safety competency

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Responsibility Matrix EPROM SOPC Remarks

Phase 2
One Day training session about PSM Competency R I To SOPC focal
Procedure persons
Presentation of PSM Competency Procedure to system R I
Owners
PSM Competency Guidelines R I
Review & approval of PSM Competency Procedure C R
(Limited to Draft & Final version)
PSM Competency Procedure rollout across the C R
company and implementation of competence
development plans
4- Workforce involvement
Phase 2
One Day training session about Workforce involvement R I To SOPC focal
guidelines persons
Presentation of Workforce involvement guidelines to R I
system Owners
Development of Workforce involvement guidelines R I
Review & approval of Workforce involvement C R
guidelines (Limited to Draft & Final version)
Workforce involvement guidelines rollout across the C R
company and implementation of actions plans
Phase 3
Workforce involvement review (Audit) R I
5- Stakeholder outreach
Phase 2
One Day training session about Workforce stakeholder R I To SOPC focal
outreach guidelines persons
Presentation of stakeholder outreach guidelines to R I
system Owners
Development of stakeholder outreach guidelines R I
Review & approval of Workforce stakeholder outreach C R
guidelines (Limited to Draft & Final version)
Stakeholder outreach guidelines rollout across the C R
company and implementation of actions
6- Process knowledge management
Phase 2
One Day training session about Process Knowledge R I To SOPC focal
management procedure persons
Presentation of Process Knowledge management R I
procedure to system Owners

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Responsibility Matrix EPROM SOPC Remarks

Process Knowledge management procedure R I
Review & approval of Process Knowledge C R
management procedure (Limited to Draft & Final
version)
Process Knowledge management procedure rollout C R
across the company and development of missing
process safety information
Phase 3
Development of Process safety Information R I
Update of current Process safety Information (if R I
needed)
7- Hazard identification and risk analysis (HIRA)
Phase 2
One Day training session about HIRA & PHA R I To SOPC focal
guidelines and procedure persons
Presentation of HIRA & PHA guidelines and procedure R I
to system Owners
Development of HIRA & PHA guidelines and procedure R I
Review & approval of HIRA & PHA guidelines and C R
procedure (Limited to Draft & Final version)
HIRA & PHA guidelines and procedure rollout across C R
the company
Phase 3
Conduct of Essential Safety studies through workshops R I With SOPC focal
and desktop studies persons
(HAZID, HAZOP, SIL (for units with ESD/BMS) , BOW
TIE, SCE, FERA & FEMCA)
Review & update the existing QRA R I With SOPC focal
persons
Presentation of Essential Safety studies R I
8- Operating procedures
Phase 2
One Day training session about Standard Operating R I To SOPC focal
procedure guidelines persons
Presentation of Standard Operating procedure R I
guidelines to system Owners
Development of Standard Operating procedure R I
guidelines
Review & approval of Standard Operating procedure C R
guidelines (Limited to Draft & Final version)
Standard Operating procedure guidelines rollout across C R
the company to develop of specific operating

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procedures
Phase 3
Development of Specific operating procedure R C
Review & approval of the Specific operating procedure C R
9- Safe work practices
Phase 2
One Day training session about Safe work practice R I To SOPC focal
guidelines and standards persons
Presentation of Safe work practice guidelines and R I
standards to system Owners
Development of Safe work practice guidelines and R I
standards
Review & approval of Safe work practice guidelines C R
and standards (Limited to Draft & Final version)
Safe work practice guidelines and standards rollout C R
across the company to develop of specific operating
procedures
Phase 3
Development of Specific work instructions R C
Implementation and monitoring of PTW R C
10- Asset integrity and reliability
Phase 2
One Day training session about Asset Integrity and R I To SOPC focal
reliability management Strategy persons
Presentation of Asset Integrity and reliability R I
management Strategy
Development of Asset Integrity and reliability R I
management Strategy
Review & approval of Asset Integrity and reliability C R
management Strategy (Limited to Draft & Final version)
Asset Integrity and reliability management Strategy C R
rollout across the company to develop of specific
operating procedures
Phase 3
Risk Based Inspection study R I As per API 581-
Software will
deployment
Reliability Centered maintenance study R I FMECA studies
Inspection of Pressure vessels, columns, heat R I
exchangers inspection procedure
Atmospheric Tanks Inspection procedure R I

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Responsibility Matrix EPROM SOPC Remarks

Piping Inspection Procedure R I
Deficiency management procedure R I
Non-Destructive testing selection procedure R I
Non-Intrusive Inspection procedure R I
Baseline Inspection procedure for Fixed Equipment R I
Corrosion under insulation inspection procedure R I
Deadleg management procedure R I
Deferral Procedure R I
Corrosion management procedure R I
Radiography inspection procedure R I
Ultrasonic Inspection procedure R I
Magnetic Particles Inspection procedure R I
Dye penetrant Inspection procedure R I
11- Contractor management
Phase 2
One Day training session about Contractor R I To SOPC focal
management procedure persons
Presentation of Contractor management procedure to R I
system Owners
Development of Contractor management procedure R I
Review & approval of Contractor management C R
procedure (Limited to Draft & Final version)
Contractor management procedure rollout across the C R
company to develop of specific operating procedures
12- Training and performance assurance
Phase 2
One Day training session about PSM training & R I To SOPC focal
performance procedure persons
Presentation of PSM training & performance procedure R I
to system Owners
Development of PSM training & performance procedure R I
Review & approval of PSM training & performance C R
procedure (Limited to Draft & Final version)
PSM training & performance procedure rollout across C R
the company to develop of specific operating
procedures
13- Management of Change
Phase 2
One Day training session about MOC R C To SOPC focal
persons
Presentation of the MOC procedure to Owners R C

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Responsibility Matrix EPROM SOPC Remarks

Development of MOC Procedure R C
Review & approval of MOC procedure (Limited to Draft C R
& Final version)
Procedure Rollout across the company C R
Phase 3
Mentoring & guidance for implementation of Mock-ups R C Implementation of
(Example of last 3 MOCs) or if new MOCs are issued MOC Mock-ups
(3 MOCs) (Example of last 3
MOCs)
14- Operational readiness
Phase 2
One Day training session about PSM training & R I To SOPC focal
performance procedure persons
Presentation of PSM training & performance procedure R I
to system Owners
Development of Standard PSSR guidelines R I
Review & approval of PSM training & performance C R
procedure (Limited to Draft & Final version)
PSM training & performance procedure rollout across C R
the company to develop of specific operating
procedures
Phase 3
Development of Specific PSSRs R C
15- Conduct of operations
Phase 2
One Day training session about Conduct of Operations R I To SOPC focal
Guidelines persons
Presentation of Conduct of Operations Guidelines to R I
system Owners
Development of Conduct of Operations Guidelines R I
Review & approval of Conduct of Operations C R
Guidelines (Limited to Draft & Final version)
Conduct of Operations Guidelines rollout across the C R
company to develop of specific operating procedures
16- Emergency management
Phase 2
One Day training session about Emergency R I To SOPC focal
Management Procedure persons
Presentation of Emergency Management Procedure to R I
system Owners
Development of Emergency Management Procedure R I

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Responsibility Matrix EPROM SOPC Remarks

Review & approval of Emergency Management C R
Procedure (Limited to Draft & Final version)
Conduct of Emergency Management Procedure rollout C R
across the company to develop of specific operating
procedures
17- Incident investigation
Phase 2
One Day training session about Incident investigation R I To SOPC focal
procedure persons
Presentation of Incident investigation procedure to R I
system Owners
Development of Incident investigation procedure R I
Review & approval of Incident investigation procedure C R
(Limited to Draft & Final version)
Incident investigation procedure rollout across the C R
company to develop of specific operating procedures
18- Measurements and metrics
Phase 2
One Day training session about PSM metrices R I To SOPC focal
persons
Presentation of PSM metrices R I
Development of PSM metrices R I
Review & approval of PSM metrices (Limited to Draft & C R
Final version)
PSM metrices rollout across the company to develop of C R
specific operating procedures
19- Auditing
Phase 2
One Day training session about PSM Auditing R I To SOPC focal
Guidelines persons
Presentation of PSM Auditing Guidelines lines to R I
system Owners
Development of PSM Auditing Guidelines R I
Review & approval of PSM Auditing Guidelines (Limited C R
to Draft & Final version)
PSM Auditing Guidelines rollout across the company to C R
develop of specific operating procedures
20- Management review and continuous improvement
Phase 2
One Day training session about Management Review R I To SOPC focal
Procedure persons

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Responsibility Matrix EPROM SOPC Remarks

Presentation of Management Review Procedure to R I
system Owners
Development of Management Review Procedure R I
Review & approval of Management Review Procedure C R
(Limited to Draft & Final version)
Management Review Procedure rollout across the C R
company to develop of specific operating procedures

Note
 SOPC shall identify the System Owners & focal persons at the kick off meeting.
System Owners: Company representative with the power to roll out the system through the
company.
Focal persons: The selected personals from every discipline who will participate during the
system development & will be empowered to implement all its pillars.
During the kick off meeting, SOPC focal persons will be divided into teams; each will be
involved in specified technical study (Process safety studies, RBI, FMECA).

5- RBI – Risk based inspection

 The scope of work is limited to Static Equipment as follow (where applicable):
- Piping Systems (limited to 2” piping and above)
- Shell & Tube Heat Exchanger
- Heater
- Column
- Reactor
- Drum
- Spherical tanks
- Filter
- Fin / Fan Cooler
- Atmospheric Tank

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- Pressure Relief Devices

- Buried Piping.
 The following asset types are excluded for RBI scope:
- Rotating Equipment
- Electrical & Instrumentation
- Structure
- Pipelines outside refinery battery limit.
 RBI Deliverables
Final Deliverables will include the following:
- Corrosion Study
- Corrosion Circuit marked up PFD
- Corrosion Circuit Table
- Corrosion Circuit marked up P&IDs along with numbering of Injection/mixing points,
Soil/air interface & Dead legs.
- Risk Assessment and Inspection planning
 Risk Rank of Equipment and Piping Corrosion Circuit for other systems.
 Inspection Plan and Inspection Tasks for Equipment and Piping corrosion circuit.
 Risk rank at systems level for Low-risk systems.
 Next Pop Test due date for respective PRVs.
 Risk distribution (individual and overall).
 Detailed inspection test plans.
 RBI software
- Deployment of an RBI software with one year license and implement all the studies into it.
- Provide 2 weeks training

6- RCM – Reliability centered maintenance

 RCM Approach

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Overall purpose of the study is adopting a risk-based approach for establishing maintenance
and inspection strategy for the identified equipment as per scope of work.
Our Method statement is study by answering following questions:
 What are the functions and associated desired standards of performance of the asset in its
present operating context (functions)?
 In what ways can it fail to fulfil its functions (functional failures)?
 What causes each functional failure (failure modes)?
 What happens when each failure occurs (failure effects)?
 In what way does each failure matter (failure consequences)?
 What should be done to predict or prevent each failure (proactive tasks and task intervals)?
 What should be done if a suitable proactive task cannot be found (default actions)?
Assessment will follow Risk Priority Numbering based Criticality approach. A risk is the chance
of something happening as a result of hazard or threat which will impact on business activity
or planned
event. Risk arises out of uncertainty. It is measured in terms of the likelihood of it happening
and the consequences if it does happen.
The methodology for this is FMECA. FMECA is a process used to identify and document the
functions,
functional failures, failure modes and failure effects of an item. It is used to determine the
significance of functional failures in terms of Safety, Environment, Operations, and Economics.
FMECA analyses would include some effort to prioritize issues in order to determine the
sequence and time-frame for the corrective actions that will be performed. The methods used
to set this priority is Risk Priority Numbers.
A risk is the chance of something happening as a result of hazard or threat which will impact
on business activity or planned event. Risk arises out of uncertainty. It is measured in terms of
the likelihood of it happening and the consequences if it does happen.

 RCM Deliverables

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Deliverables upon completion of the study is the study worksheet for the rotating equipment
for SOPC units (previously determined above) identify the function, functional failure, effect,
Si, classification, failure mode, occurrence, control, control type, DI, RPNI, action.

7- Inputs Requirements
The following are required per each unit – to be provided from SOPC (If available) prior to the
studies.
- General plot plan of each unit.
- Process Schematic for each unit either in DCS screenshot form or any other useful form
- Operating manual for individual unit – in consolidated single document in pdf form
- PFD (all set) –in pdf form
- P&ID (all set) –in pdf form
- Material balance –pdf and native EXCEL form
- Energy balance –in pdf and native EXCEL form
- MSD (Material selection diagram) –in pdf form
- Equipment redundancy / service level
- Equipment Data Sheet – Process and Mechanical
- Equipment Drawings – General arrangement and Detailed drawing – in pdf form
- Mechanical line list – in pdf and native EXCEL form
- Piping class/ line class/ piping specification document – in pdf consolidated form
- Insulation line list
- Inputs in Excel form including the information about PRV including following information:
 Type of PRV (Conventional / Balanced Bellow / Pilot Operated / with Rupture disk).
 PRV discharge location (Atmosphere / Flare / Closed)
 Operating, Design and Release set pressure
 MOC of Valve trim and spring exposed to process fluid
 Fluid service severity that might jeopardize valve disk free movement (Mild, Moderate,
Severe)

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 Overpressure case of the protected equipment / piping circuit for which PRV is
designed.
- A consolidated report listing the last intrusively inspected dates in past for respective
equipment
- Major Inspection Reports for last three (3) occasions for respective static equipment
- Major Maintenance / repair report for last three (3) occasions for respective rotating
equipment
- Other relevant information pertaining to maintenance history
- Track records related to plant upset
- Additional information related to the specific chemical composition of the handled fluid
services
- Service start date, most conservative operating case for the unit
- Previous RCAs related to the equipment. (If any)
- CMMS historical data and maintenance plans
- Rotating equipment manuals.
- Condition monitoring reports where applicable
- Inspection history
- Preventive maintenance, condition monitoring, inspection and operator inspection &
monitoring program
- Current basis of determination of Severity, Occurrence and Detection classification / rating
(number)
- Company maintenance and inspection philosophy / strategy / program.

In addition, SOPC should clarify the following (If available) as these inputs will form the basic
basis of RBI study and are required to be entered in the software setting prior to starting RBI
assessment.
 Company’s risk matrix including the info, on 1) POF & Damage Factor Ranges, 2) COF
categories & its ranges and 3) Risk Categories with Matrix cell settings

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 Typical Outage days for different failure modes (small hole, medium hole, large hole and
rupture) for different equipment types and piping circuit sizes (maximum NB)
 Production down time cost @ day for individual unit, impact on unit production by
unavailability of respective individual equipment and piping circuit
 Total equipment cost for individual unit
 Population Density for individual unit and Injury cost @ fatality
 Maximum Acceptable Risk Target in form of Damage Factor, Affected Area, Total Cost,
PLL
 Maximum and Minimum cap of Inspection Interval generally adopted by company.
 Service start date, Current evaluation date and Future evaluation date for RBI assessment

Important Note
EPROM assumes availability of all above mentioned required data. Incase of any unavailable
data, EPROM will conduct the study - if possible- in conservative manner based on
engineering assumption. All the assumption will be submitted in questionnaire form & SOPC to
fill & approve it in time to proceed in the study.

8- Asset count
The asset count to undergo the RBI & RCM studies are as follow-
SN Unit Asset count
346 Fixed equipment
1 Process units 172 pumps + 15 compressors
14700 piping tag
550 PSV
160 Fixed equipment
2 Utilities & tank farms 320 pumps + 6 compressors + 1 turbine
6000 piping tag
250 PSV

 Any addition or submission will have an impact on the project time frame & cost.

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 Any additional asset over the above-mentioned table will be considered as extra cost. The
cost will be clarified in a “cost time & resources” documentation prior any work, SOPC
approval on the CTR is mandatory to proceed.

9- Training
9.1 In addition to the awareness & shadowing with SOPC focal persons, we offer capacity
building training program as follow-
1- Top & senior managers (2 waves, 15 trainees per wave) for 2 days.
2- Engineers (7 waves, 15 trainees per wave) for 5 days.
3- Technicians (134 waves, 15 trainees per wave) for 1 day.
9.2 Apply a safe operation course training for 250 operating personnel (10 waves, 25 trainees
per wave) for 5 days.
9.3 Provide training on the delivered RBI software for SOPC RBI team for 2 weeks.

Note:
Training shall be carried out at SOPC. SOPC to provide the proper training rooms.
The training evidence (attendance sheet, evaluated test) will be provided.

10-Codes & standards

Provide the latest editions of the following codes & standards-

ASME I API 510 API 573 API 660

ASME II API 570 API 560 API 661
ASME V API 572 API 577 API 663
ASME VIII div.1 API 574 API 650 ASME B31.1
ASME IX API 571 API 653 ASME B31.3
ASME B16.5 ASME PCC-2 API 576 ASME B31.4

11-Deliverables
1- GAP Analysis report.

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2- A PSM system as per CCPS cover the 20 elements as mentioned in details above &
included the following-
 Incentive & Disciplinary program.
 Action tracking system.
 Non-routine work lists.
 Audit program & related documents.
 PSM competency & training assurance program.
 SCE register.
 PSM lesson learn plan (beacon).
 PSV Maintenance procedure.
 KPIs follow-up procedure.
 PSM manual.
 Fitness for duty program.
3- Deliver RBI software as mentioned in clause 5.0
4- A training program as mentioned in details in clause 9.0
5- Deliver an engineering library as mentioned in details in clause 10.0
6- Reporting:
 EPROM will provide a progress report for all activities (monthly) to SOPC.
 Communication Matrix to be provided. “Indicating intervals & approval method “

12-WORK LOCATION
- SOPC
- EPROM Headquarters (Alexandria).
 Responsibility for site configuration is as below
Item SOPC EPROM
10 Laptops R
TCF for EPROM team R
Suitable empty area for TCF R
Utilities for the TCF & offices (water,
R
sewer, electricity, telephone line, internet)
4 Offices for achieving (1) R
Offices furniture R

(1) : SOPC to provide 4 offices (2 for archiving & 2 for the working team) each room shall
be able to accommodate 5 engineers.

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13- ORGANIZATION
EPROM Project team will comprise of highly qualified engineers covering a vast range of specialties as
shown in the following table:

# Position Required No. Level

1 Project Manager 1 9
2 Focal point 2 8
3 Process safety engineer 4 8
4 Functional safety engineer 2 8
5 Operation engineer 2 8
6 Process engineer 2 8
7 Asset integrity leader 1 8
8 RBI engineer 1 8
9 Reliability RCM engineer 1 8
10 Rotating engineer 2 8
11 Instrumentation engineer 3 8
12 Electrical engineer 2 8
13 Static & piping engineer 2 8
14 Corrosion engineer 1 8
15 Inspection engineer 3 8
16 DCC 1 8
17 Planner 1 8
18 Helper 4 3

14- PROJECT DURATION

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The preliminary project schedule is 41 months as presented in Gantt chart as per attachment #1.
The presented schedule is based on the asset count shown in clause 8.0 & in consistence with the
responsibility matrix shown in clause 4.2. Any additional asset or scope will have an impact on the
estimated project duration.
The estimated project may subject to modification after mutual approval between EPROM & SOPC.

15- PRICES AND TERMS OF PAYMENT.

The project cost shall be reimbursed as lump sum (xxxx million EGP) as shown in below-
Cost (Egyptian pound -
SN Item
LE)
Gap analysis & PSM system
1
development
2 PSM system & studies
3 Asset integrity system
4 RBI studies
5 RCM studies
Standard library, Software (license &
6
training)
Capacity building (company scale)
7
training

 The payment shall be in line with the following milestones

SN Activity Percentage of payment

1 Down payment against LG from EGPC 25%
2 Kick off meeting & Mobilization 10%
3 GAP analysis establishment 10%
4 RBI software deployment 20%
5 Non-operating procedures establishment 20%
6 Risk assessment studies 20%
7 System implementation & rollout 15%
8 Audit 5%

Note: Deduct 25 % of each invoice as down payment.

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 Payment terms

- The price is exclusive of 14% VAT or any other taxes.

- Based on the above-mentioned milestones the due amounts will be paid by SOPC against
milestones’ invoices. SOPC shall pay to EPROM its dues as per CSA.
- Any estimated cost and time depend on the scope mentioned in the scope of work section, and
any change to this scope during the projects execution it will be handled as change request and
will be assessed separately.
- Any delay for any reasons out of EPROM team, will be excluded from the schedule without
charging any penalty, and an updated project plan will be sent to SOPC based on the number
of days impacted.
- Bad weather impact on the project is excluded from the time schedule, and an updated project
plan will be sent to SOPC accordingly.
- Reviewing cycles will be based on the communication matrix which will be set up at the kick off
meeting, the reviewing period will be within 10 working days from the delivery date, after this
period the deliverables will be considered as approved versions.
4.

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