PSSR Audit Observation Report

Date of PSSR: PSSR Reference Number:

Plant: Diesel Tanks and Diesel Unloading Equipment/System: Diesel Tanks
System Reference Number:

Plant /Facility Manager: Mr Upadhyay Bhusan PSSR Coordinator: Mr. Ratan Singh
PSSR Review Team Members
1 Shailesh Dubey - PSSR Leader
2 Mr. Ravi Ramasamy – Asset Integrity
3 Muhammad Chaudhry- Mechanical
4 Raja Saminathan- Electrical
5 Nnamdi Azubuike- HSE
6 Newman Orijedje- HSE

TO be filled by PSSR Review team To be filled by Plant Manager/ HOD

Finding type
S. Checklist Category Observer name Date
Checklist item (Document Finding /Observation ( A or B)
Action required Action by Function Responsible person Name Target Date Punch Clearance Action
Completed
No Ref No or Field)
Are points of isolation clealy marked /labelled and Mark up P&ID should show blind position . All Blinds
1 1.1.2 Document Mark up P&ID nort showing blind positions A Ravi Ramasamy Operation Hamid 2-Sep-22
readily accessible in field should be tagged as per mark up

2 Locations of Fire extinguisher, PA system, MCP marked B Ravi Ramasamy To mark with ZEBRA painting Operation/OIL Ratan/Alam 7-Sep-22
1.1.2.22 Field Locations not marked
with ZEBRA painting

Bump hazard at the sprinkler water Zebra marking (Black/yellow) stripes to be painted
Field A Ravi Ramasamy on bump/trip hazard point in all six tanks Operation/CTL Ratan/Ranjit 5-Sep-22
collection tray when climbing ladder,
3 Have bump/trip hazards been identified and all sharp
1.1.3 Unwanted cable trays inside dyke are trip
edges removed? Field B Ravi Ramasamy May be removed and reused elsewhere Electrical/OIL Raja/Tarun/Ratan 7-Sep-22
hazard
Concrete covers lying near the pump area
Field B Shailesh Dubey To be fixed properly Electrical/OIL Raja/Tarun/Ratan 7-Sep-22
are trip hazard

4 Has proper guarding, handrails/barriers, been provided A Ravi Ramasamy Provide Chains/Barricades in the ladder opening to Operation/CTL Ratan/Ranjit/Sunil 7-Sep-22
1.1.4 Field There is fall hazard on top of Diesel Tanks Foam champer
to prevent falls?

5 1.1.8 First aid boxes provided Field No first Aid box A Ravi Ramasamy First Aid box to be provided in office or at SRR11 Operation/Safety Ratan/Mfon 5-Sep-22

6 The cross over ladder from C,D tanks to E F B Ravi Ramasamy Steps in the slope required for safe cross over Operation/Civil Ratan/Renato 5-Sep-22
1.1.10 Platforms ladders checked Field
Tank road is ending in drain channel.
7 1.1.14 Safety boards displayed Field No safety boards B Ravi Ramasamy To provide safety boards as needed Operation/Safety Sunil/Mfon 7-Sep-22
8 1.1.8 Assembly point marked Field Assembly point Not marked A Ravi Ramasamy To mark assembly point Operation/Safety Ratan/Mfon 5-Sep-22

Has safe access been provided to those parts of the

machinery that requires operator access for operation,
Tank inlet / outlet MOV's are diffcult to operate Muhammad To operate the valve in tankage area some
9 1.2.4 adjustment, service, maintenance or repair, i.e. Field B Operation Upadhyay 7-Sep-22
manually Chaudhry extended platforms are required,
elimination of slip, trip, trap, crush, entanglement, fall,
bump and cut hazards?

10 2.1.1 Material Safety Data Sheet Document MSDS not available A Ravi Ramasamy MSDS to be made available to O&M team Operation Sunil/Dayan 2-Sep-22

11 Have project PHAs/HAZOP been approved and a final A Ravi Ramasamy To provide Hazop closeout report Operation Dileep 2-Sep-22
2.3.1 Document Hazop action taken report not provided
project safety report been prepared?

12 Format III documents for CP system not A Ravi Ramasamy FORMAT III documents for CP system and any other Operation/CTL Ratan/Ranjit/Battercharie 5-Sep-22
2.4.5.1 Installation of all piping and equipment as per drawings FORMAT III missing systems in the PSSR scope to be provided
available

No short bolting observed, However, Molykote

Muhammad
13 2.4.5.2 Short bolt audit Field on valve stems & Flange bolts of main inlet B Chaudhry Molykote to be applied on all bolts Operation/OIL Alam Manower/Ratan 5-Sep-22
valves of Tanks (714-TT-1404) not available

14 Document/ Many drain valves were found in open position A Ravi Ramasamy List of LPD and HPV to be made and closure of Operation Sunil/Hamid 2-Sep-22
2.4.5.3 All low point drains and high point vents are blinded valves and blind to be confirmed
Field though blind was in place
All temporary blinds are removed.Updated status of Document/ B Shailesh Dubey Master blind register to be prepared including all the Operation Sunil/Hamid 5-Sep-22
Blind record is not available.
15 permanent blind is available. Field blinds and their actual position.
2.4.5.9
Document/ Temporary/ permanent stariner installation list to
Temporary strainers and permanent strainers Details not available B Ramasamy Ravi Operation Sunil/Hamid 5-Sep-22
field be prepared and verified

Field CSO/ CSC not in place A Ramasamy Ravi To apply CSO/CSC as per P&ID . Operation Sunil/Hamid 5-Sep-22
16 2.4.5.25 CSO/CSC valve status
Document CSO/CSC Register not available B Ramasamy Ravi To maintain a register for CSO/CSC status checking Operation Sunil/Hamid 5-Sep-22

17 2.4.5.12 All temporary equipmentfor construction are removed Field Generators for construction still in place A Ramasamy Ravi All temporary equipment to be removed Operation Ratan 5-Sep-22

Corrosion probe 733-CP/CT-1601installed To check EIL design basis and decide the forward
18 2.4.5.18 Corrosion coupon/ Probe installed Field A Ramasamy Ravi Operation Upadhyay 2-Sep-22
without isolation valve path- Install Isolation valve

Document Diesel receiving procedure needs to be updated A Ramasamy Ravi Update procedure as per the E Mail comments Operation Upadhyay/Hamid 2-Sep-22
19 2.6.6 Have operating procedures prepared
SOP Index is not available and SOP's are not Prepare SOP Index and get all SOP's signed off by
Document B Shailesh Dubey Operation Sunil/Hamid 5-Sep-22
signed off. approving authority
Communication protocol/procedure with Marine Communication procedure /protocol to be prepared
20 2.6..6.9 Communication procedure Document A Ramasamy Ravi Operation Upadhyay 5-Sep-22
during Diesel recipt not available and agreed with Marine
21 Equipment hand over/ takeover procedure between Equipment hand over/ takeover procedure B Shailesh Dubey Prepare pump changeover, handover/takeover for Operation Sunil/Arun/Hamid 5-Sep-22
2.6.6.12 Document
production & maintenance between production & maintenance not available maintenance procedures

Shift handover/ takeover procedures are not B Shailesh Dubey

22 2.6.6.15 Shift handover/ takeover procedures are finalized. Document Shift handover/ takeover procedures to be prepared Operation Sunil/Arun/Hamid 5-Sep-22
available

23 Has specific process (or job task) training been given to B Shailesh Dubey Record of Training of all SOP's to O&M team to be Operation Ratan/Sunil 7-Sep-22
2.7.1 Document SOP training to all O&M team not given
all personnel? made available
24 A Ramasamy Ravi FA and FF training for all to be done and records to Operation/Safety Ratan/Mfon 7-Sep-22
2.7.7 & 2.7.9 Basic First Aid training/ Firefighting training Document Training Not yet done be available

25 A Ramasamy Ravi Interlocks,alarms to be tested and test records to be Operation/Electrical/Instrument Haresh/Raja/Goswamy 7-Sep-22
2.9 Interlocks Document Testing record not available available

26 3.1 Are all secondary containment adequate Field Pipe entry to Tank Dyke not yet sealed A Ramasamy Ravi To seal all pipe entry points OIL Alam Manower/Farouk 2-Sep-22

27 OWS system is modified to store OW in Diesel A Ramasamy Ravi IFC P&ID to be updated or MOC to be approved Field Engineering/EIL Upadhyay 7-Sep-22
3.12 OWS system Field
Tank
Field 2 Nos 2000 GPM monitor not installed A Ramasamy Ravi To Install OIL Mishra/Chuks 2-Sep-22
Foam supply point to tanks- Flange open, no A Ramasamy Ravi To install connectors Operation/CTL Upadhyay/Ranjit 5-Sep-22
Field
connector
Field Fire hose cabinets not installed A Ramasamy Ravi To install OIL/AG-Dangote Renato/Mishra/Ratan 5-Sep-22
28 4.3 Are fire protection facilities adequate? Field Fire water system not charged A Ramasamy Ravi To charge Operation Chukwuma 2-Sep-22
Fire hose connectors (11/2"" to 2,1/2"" to Fire A Ramasamy Ravi To arrange connectors/couplings OIL Mishra/Chuks 2-Sep-22
Field
truck not available
Foam connection coupling to 2000 GPM monitor A Ramasamy Ravi To arrange couplings OIL Mishra/Chuks 2-Sep-22
Field
not available
29 4.9 Mock drill Field Not conducted A Ramasamy Ravi To conduct emergency drill of fire scenario Operation/Safety Ratan/Mfon 5-Sep-22
30 Some grounding connections missing as shown A Ramasamy Ravi To provide grounding connections Electrical/OIL Raja/Tarun/Femi 2-Sep-22
5.5 Does earthing/grounding comply Field
during PSSR
31 Are first aid stations, single line drawings and PPE Arc flash suit not available in SS. Mitigation plan B Raja Saminathan Arc flash suit to be procured and made available Operation/Safety Upadhyay and Ravi 7-Sep-22
5.8 Field
requirements available in Sub stations available
Lighting in the plant including street lighting is
32 5.20 adequate to enable all activities safely. Illumination Field Illumination survey not done. B Raja Saminathan Illumination survey to be done. Operation/Electrical Ratan/Raja 7-Sep-22
survey done.
33 Substations & cellar rooms are clean. No unwanted Unwanted cable sleeves, loose cables observed in B Raja Saminathan Cable cellar cleaning to be done Operation/Electrical Ratan/Raja/Tarun 7-Sep-22
5.23 Field
material stored in the sub-stations. cable celler.
34 Cathodic protection is operational for all Underground A Raja Saminathan Operation/Electrical Ratan/Raja 5-Sep-22
5.26 Field Not in operation
Piping
Firefighting plan for Diesel storage area to be
35 6.1 Written Fire Protection Plan available Document Fire protection plan not available A Ramasamy Ravi Operation/Safety Ratan/Mfon/Upadhyay 5-Sep-22
developed
Some trenches are not covered and some
36 A Ramasamy Ravi Trenches to be covered and housekeeping to be Operation/Electrical/OIL Renato/Ratan/Raja/Tarun 2-Sep-22
16.1.1. All construction debris removed Field construction debris still remain. Dyke drain pits done. Dyke drain pits to be cleaned
debris
37 PA system operational. Checked for clarity & volume A Ramasamy Ravi PA System to be made operational Operation Upadhyay 5-Sep-22
17.3 Field PA system is not tested and operational
with machinery
38 Platform & Railings Field Some platforms & railings required paintung B Muhammad ChaudhryPainting of all platforms and railings. Operation Upadhyay 7-Sep-22
 Date of PSSR:
Plant: Diesel Tanks and Diesel Unloading

Plant /Facility Manager: Mr Upadhyay Bhusan

PSSR Review Team Members
1 Shailesh Dubey - PSSR Leader
2 Mr. Ravi Ramasamy – Asset Integrity
3 Muhammad Chaudhry- Mechanical
4 Raja Saminathan- Electrical
5 Nnamdi Azubuike- HSE
6 Newman Orijedje- HSE

TO be filled by PSSR Review team

Finding type
S. Checklist (Document
Checklist item
No Ref No or Field)

1 Are points of isolation clealy marked

1.1.2 Document
/labelled and readily accessible

3 Have bump/trip hazards been identified

1.1.3 Field
and all sharp edges removed?

4 Has proper guarding, handrails/barriers,

1.1.4 Field
been provided to prevent falls?

5 1.1.8 First aid boxes provided Field

8 1.1.8 Assembly point marked Field

10 2.1.1 Material Safety Data Sheet Document

 Have project PHAs/HAZOP been
11 2.3.1 approved and a final project safety report Document
been prepared?

12 Installation of all piping and equipment FORMAT

2.4.5.1
as per drawings III

14 All low point drains and high point vents Document/

2.4.5.3
are blinded Field
16 2.4.5.25 CSO/CSC valve status Field

17 All temporary equipmentfor

2.4.5.12 Field
construction are removed
18 2.4.5.18 Corrosion coupon/ Probe installed Field

19 2.6.6 Have operating procedures prepared Document

20 2.6..6.9 Communication procedure Document

24 Basic First Aid training/ Firefighting

2.7.7 & 2.7.9 Document
training
25 2.9 Interlocks Document

26 3.1 Are all secondary containment adequate Field

27 3.12 OWS system Field

Field
Field
Field
28 4.3 Are fire protection facilities adequate? Field
Field

Field
29 4.9 Mock drill Field
30 5.5 Does earthing/grounding comply Field

34 Cathodic protection is operational for all

5.26 Field
Underground Piping
35 6.1 Written Fire Protection Plan available Document
36 16.1.1. All construction debris removed Field

37 PA system operational. Checked for

17.3 Field
clarity & volume with machinery
Locations of Fire extinguisher, PA
2 1.1.2.22 system, MCP marked with ZEBRA Field
painting

Field
3 Have bump/trip hazards been identified
1.1.3
and all sharp edges removed?
Field

6 1.1.10 Platforms ladders checked Field

7 1.1.14 Safety boards displayed Field

Has safe access been provided to those
parts of the machinery that requires
operator access for operation,
9 1.2.4 adjustment, service, maintenance or Field
repair, i.e. elimination of slip, trip, trap,
crush, entanglement, fall, bump and cut
hazards?

13 2.4.5.2 Short bolt audit Field

All temporary blinds are

Document/
removed.Updated status of permanent
15
Field
2.4.5.9 blind is available.
Temporary strainers and permanent Document/
strainers field
16 2.4.5.25 CSO/CSC valve status Document

19 Document
2.6.6 Have operating procedures prepared
Equipment hand over/ takeover
21 2.6.6.12 procedure between production & Document
maintenance

22 Shift handover/ takeover procedures are

2.6.6.15 Document
finalized.
23 Has specific process (or job task)
2.7.1 Document
training been given to all personnel?
Are first aid stations, single line
31 5.8 drawings and PPE requirements Field
available in Sub stations
 Lighting in the plant including street
32 lighting is adequate to enable all
5.20 Field
activities safely. Illumination survey
done.
Substations & cellar rooms are clean. No
33 5.23 unwanted material stored in the sub- Field
stations.
38 Platform & Railings Field
 PSSR Audit Observation Report

PSSR Reference Number:

Equipment/System: Diesel Tanks
System Reference Number:

PSSR Coordinator: Mr. Ratan Singh

be filled by PSSR Review team

Category (
Finding /Observation Observer name
A or B)

Mark up P&ID nort showing blind positions A Ravi Ramasamy

Bump hazard at the sprinkler water collection tray

A Ravi Ramasamy
when climbing ladder,

There is fall hazard on top of Diesel Tanks A Ravi Ramasamy

No first Aid box A Ravi Ramasamy

Assembly point Not marked A Ravi Ramasamy

MSDS not available A Ravi Ramasamy

Hazop action taken report not provided A Ravi Ramasamy

Format III documents for CP system not available A Ravi Ramasamy

Many drain valves were found in open position though A Ravi Ramasamy
blind was in place
CSO/ CSC not in place A Ramasamy Ravi

Generators for construction still in place A Ramasamy Ravi

Corrosion probe 733-CP/CT-1601installed without A Ramasamy Ravi

isolation valve

Diesel receiving procedure needs to be updated A Ramasamy Ravi

Communication protocol/procedure with Marine during A Ramasamy Ravi

Diesel recipt not available

Training Not yet done A Ramasamy Ravi

Testing record not available A Ramasamy Ravi

Pipe entry to Tank Dyke not yet sealed A Ramasamy Ravi

OWS system is modified to store OW in Diesel Tank A Ramasamy Ravi

2 Nos 2000 GPM monitor not installed A Ramasamy Ravi

Foam supply point to tanks- Flange open, no connector A Ramasamy Ravi

Fire hose cabinets not installed A Ramasamy Ravi

Fire water system not charged A Ramasamy Ravi
Fire hose connectors (11/2"" to 2,1/2"" to Fire truck not A Ramasamy Ravi
available
Foam connection coupling to 2000 GPM monitor not A Ramasamy Ravi
available
Not conducted A Ramasamy Ravi
Some grounding connections missing as shown during A Ramasamy Ravi
PSSR

Not in operation A Raja Saminathan

Fire protection plan not available A Ramasamy Ravi

Some trenches are not covered and some construction A Ramasamy Ravi
debris still remain. Dyke drain pits debris
PA system is not tested and operational A Ramasamy Ravi

Locations not marked B Ravi Ramasamy

Unwanted cable trays inside dyke are trip hazard B Ravi Ramasamy

Concrete covers lying near the pump area are trip

B Shailesh Dubey
hazard
The cross over ladder from C,D tanks to E F Tank road B Ravi Ramasamy
is ending in drain channel.
No safety boards B Ravi Ramasamy

Tank inlet / outlet MOV's are diffcult to operate B Muhammad

manually Chaudhry

No short bolting observed, However, Molykote on

Muhammad
valve stems & Flange bolts of main inlet valves of B Chaudhry
Tanks (714-TT-1404) not available

Blind record is not available. B Shailesh Dubey

Details not available B Ramasamy Ravi

CSO/CSC Register not available B Ramasamy Ravi

SOP Index is not available and SOP's are not signed B Shailesh Dubey
off.

Equipment hand over/ takeover procedure between B Shailesh Dubey

production & maintenance not available

Shift handover/ takeover procedures are not available B Shailesh Dubey

SOP training to all O&M team not given B Shailesh Dubey

Arc flash suit not available in SS. Mitigation plan B Raja Saminathan
available
Illumination survey not done. B Raja Saminathan

Unwanted cable sleeves, loose cables observed in cable B Raja Saminathan

celler.
Some platforms & railings required paintung B Muhammad Chaudhry
ation Report

e Number:
m: Diesel Tanks
Number:

Mr. Ratan Singh

To be filled by Plant Manager/ HOD

Action required Action by Function

Mark up P&ID should show blind position . All

Operation
Blinds in field should be tagged as per mark up

Zebra marking (Black/yellow) stripes to be

painted on bump/trip hazard point in all six Operation/CTL
tanks

Provide Chains/Barricades in the ladder

Operation/CTL
opening to Foam champer

First Aid box to be provided in office or at

Operation/Safety
SRR11
To mark assembly point Operation/Safety

MSDS to be made available to O&M team Operation

To provide Hazop closeout report Operation

FORMAT III documents for CP system and any

other missing systems in the PSSR scope to be Operation/CTL
provided
List of LPD and HPV to be made and closure of
valves and blind to be confirmed Operation

To apply CSO/CSC as per P&ID . Operation

All temporary equipment to be removed Operation

To check EIL design basis and decide the Operation

forward path- Install Isolation valve
Update procedure as per the E Mail Operation
comments
Communication procedure /protocol to be
Operation
prepared and agreed with Marine
FA and FF training for all to be done and Operation/Safety
records to be available
Interlocks,alarms to be tested and test records Operation/Electrical/Instrument
to be available

To seal all pipe entry points OIL

IFC P&ID to be updated or MOC to be Field Engineering/EIL

approved
To Install OIL
To install connectors Operation/CTL
To install OIL/AG-Dangote
To charge Operation
To arrange connectors/couplings OIL

To arrange couplings OIL

To conduct emergency drill of fire scenario Operation/Safety
To provide grounding connections Electrical/OIL

Operation/Electrical

Firefighting plan for Diesel storage area to be

developed Operation/Safety
Trenches to be covered and housekeeping to
be done. Dyke drain pits to be cleaned Operation/Electrical/OIL

PA System to be made operational Operation

To mark with ZEBRA painting Operation/OIL

May be removed and reused elsewhere Electrical/OIL

To be fixed properly Electrical/OIL

Steps in the slope required for safe cross over Operation/Civil

To provide safety boards as needed Operation/Safety

To operate the valve in tankage area some Operation

extended platforms are required,

Molykote to be applied on all bolts Operation/OIL

Master blind register to be prepared including Operation

all the blinds and their actual position.
Temporary/ permanent stariner installation
list to be prepared and verified Operation
To maintain a register for CSO/CSC status
Operation
checking
Prepare SOP Index and get all SOP's signed off
by approving authority Operation

Prepare pump changeover, handover/takeover Operation

for maintenance procedures

Shift handover/ takeover procedures to be Operation

prepared
Record of Training of all SOP's to O&M team Operation
to be made available

Arc flash suit to be procured and made Operation/Safety

available
Illumination survey to be done. Operation/Electrical

Cable cellar cleaning to be done Operation/Electrical

Painting of all platforms and railings. Operation

ager/ HOD

Punch
Responsible person Name Target Date Clearance Date Completed
Action

Hamid 2-Sep-22 Completed

Ratan/Ranjit 5-Sep-22 Ongoing

Ratan/Ranjit/Sunil 7-Sep-22 Completed

Ratan/Mfon 5-Sep-22

Ratan/Mfon 5-Sep-22

Sunil/Dayan 2-Sep-22 Completed

Dileep 2-Sep-22 Completed

Ratan/Ranjit/Battercharie 5-Sep-22 Ongoing

Sunil/Hamid 2-Sep-22 Completed

Sunil/Hamid 5-Sep-22

Ratan 5-Sep-22

Upadhyay 2-Sep-22

Upadhyay/Hamid 2-Sep-22 Completed

Upadhyay 5-Sep-22 Completed

Ratan/Mfon 7-Sep-22

Haresh/Raja/Goswamy 7-Sep-22

Alam Manower/Farouk 2-Sep-22 Completed

Upadhyay 7-Sep-22
Mishra/Chuks 2-Sep-22
Upadhyay/Ranjit 5-Sep-22
Renato/Mishra/Ratan 5-Sep-22 Completed
Chukwuma 2-Sep-22 Completed

Mishra/Chuks 2-Sep-22

Mishra/Chuks 2-Sep-22
Ratan/Mfon 5-Sep-22
Raja/Tarun/Femi 2-Sep-22 Ongoing

Ratan/Raja 5-Sep-22

Ratan/Mfon/Upadhyay 5-Sep-22
Renato/Ratan/Raja/Tarun 2-Sep-22 Ongoing

Upadhyay 5-Sep-22

Ratan/Alam 7-Sep-22

Raja/Tarun/Ratan 7-Sep-22

Raja/Tarun/Ratan 7-Sep-22 Ongoing

Ratan/Renato 5-Sep-22 Ongoing

Sunil/Mfon 7-Sep-22

Upadhyay 7-Sep-22 Ongoing

Alam Manower/Ratan 5-Sep-22 Completed

Sunil/Hamid 5-Sep-22 Completed

Sunil/Hamid 5-Sep-22 Completed

Sunil/Hamid 5-Sep-22 Completed

Sunil/Hamid 5-Sep-22 Completed

Sunil/Arun/Hamid 5-Sep-22 Completed

Sunil/Arun/Hamid 5-Sep-22 Completed

Ratan/Sunil 7-Sep-22 Completed

Upadhyay and Ravi 7-Sep-22

Ratan/Raja 7-Sep-22

Ratan/Raja/Tarun 7-Sep-22 Ongoing

Upadhyay 7-Sep-22