Process Integrity

Site Q-Round
Q03a Process Integrity

• Please allow 30 to 60 minutes to complete this Q-Round Check Sheet.
• Your input and participation in this Q-Round is valuable to the Crux "Right First Time" (RFT) program to ensure no rework or unrevealed defects with "No Blocks, No Leaks, No Trips".
• Please take evidence photos during the Q-Round for upload at the end of this Check Sheet.
• If any question is not applicable, skip the question and move forward.

Q-Round Date

Name of Person Completing the Check Sheet

Company of Person Completing the Check Sheet

Sub-Contractor

Other

Area / Location

Equipment Name / Number (if applicable)

Name and Company of Participants

RFT Awareness

1.1 - Have Supervisors and workforce undertaken RFT Training & demonstrate RFT Q03a Process Integrity Awareness, in particular area?

Process Integrity

2.1 - Optimal operating windows clearly outlined, with real-time monitoring for quick deviation detection and established protocols, including rapid shutdown procedures for swift responsive actions: - Operating windows: highlighting the optimal operational area - Operating envelope: indicating the acceptable space, often outlined by alarms or instrument PV limits - Design envelope: shaped by equipment's physical constraints and managed through trip/physical relief devices.

2.2 - For instruments with alarms and trips, a comprehensive validation process is in place, covering: - Setpoint validation: Confirming alarms are accurately set according to the alarm/trip list. - Enabled status validation: Ensuring alarms are activated. - Calculation validation: Verifying that calculations align accurately with the documented parameters.

2.3 - Control loop tuned by a competent person, tuning parameters uploaded to the offline database, and recorded in the external tuning database.

2.4 - Is the reliability of utility supplies regularly assessed, with implemented backup systems or alternative sources to mitigate interruptions, and are periodic audits conducted to identify potential weaknesses in utility infrastructure?

2.5 - Are product quality control measures enhanced through improved monitoring, and is there implementation of real-time analysis and feedback systems to promptly identify off-spec products?

2.6 - Have clear procedures been established for handling and managing off-spec products, including disposal or reprocessing?

2.7 - Are weather monitoring systems in operation to anticipate and prepare for adverse conditions, with contingency plans developed for heavy rain or other environmental factors that may impact production, and are regular maintenance checks conducted on equipment prone to weather-related issues?

2.8 - Is there a robust preventive maintenance program established for critical equipment, with the implementation of condition-based monitoring for the early detection of equipment issues, and are regular inspections and testing conducted to identify potential reliability concerns?

2.9 - Are operating procedures regularly reviewed and updated to prevent overpressure situations, is proper training ensured for operators on safe operating practices, and is a comprehensive process safety management system in place to identify and mitigate potential hazards?

2.10 - Are sample conditioning practices evaluated and enhanced to improve accuracy in product analysis, and are regular calibration and validation procedures implemented for analysis equipment, with training provided to personnel involved in sample collection and analysis?

2.11 - Effectively incorporate corrosion-resistant materials for pipelines and ensure their suitability for corrosive service piping.

2.12 - Corrosion monitoring and testing are routine as part of maintenance to ensure effective corrosion management.

2.13 - Specific corrosion mitigation strategies, encompassing industry-standard measures like coatings, cathodic protection, material selection, proper design, regular inspection and maintenance, environmental control, alloy systems, flow assurance, advanced monitoring techniques, and specific methods like dewpointing and CI (Corrosion Inhibitor) injection, implemented and regularly reviewed for their effectiveness?

2.14 - Are strict protocols in place for handling and storing catalysts, is the condition of catalysts regularly monitored and analysed to detect contamination, and are procedures reviewed and updated to prevent contaminants from entering the system?

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