Guideline

TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

08/23/2012

Revisit Date:

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

1/9
REV.

3
Trueman Hirschfeld

REVISIONS
Rev #
1
2

Nature of Change
The development of the
Commissioning PHR
Guideline.
Formatting changes

Rev'n by

Approved by
document owner

Issue Date
YYYY/MM/DD

Business
Systems
Group

PHR Review
Committee

2012/08/15

AD / TH

Trueman Hirschfeld

2012/08/23

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

08/23/2012

Revisit Date:

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

2/9
REV.

3
Trueman Hirschfeld

Table of Contents
1.0

CONTEXT .................................................................................................................... 3

2.0

PURPOSE ................................................................................................................... 3

3.0

REFERENCE DOCUMENTATION .............................................................................. 3

4.0

COMMISSIONING PHRS ........................................................................................... 3

4.1

ATTENDEES ............................................................................................................ 5

5.0

PREPARATION FOR THE PHR MEETING ................................................................. 5

6.0

USE OF THE PHR TEMPLATE (NAV-TP-0019-C)..................................................... 6

6.1

METHODOLOGY TAB ............................................................................................. 6

6.2

GENERAL HAZARDS CHECKLIST TAB ................................................................. 6

6.3

PROCESS HAZARDS REVIEW MINUTES TAB...................................................... 6

6.4

WORKERS SIGN OFF SHEET ................................................................................ 8

7.0

TYPICAL PHR MEETING AGENDA ............................................................................ 8

8.0

APPENDICES .............................................................................................................. 9

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

1.0

08/23/2012

Revisit Date:

3/9
REV.

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

3
Trueman Hirschfeld

CONTEXT

It is Vale's policy to provide employees with a safe place to work, to safeguard company property and
to conduct operations in a manner not hazardous to the public or environment. Process Hazards
Reviews (PHRs) are conducted for all projects at the FEL Stages, Detailed Design, Construction and
Commissioning stages.

PHRs are also conducted for other activities where merited, e.g. Operations or Maintenance
work that poses significant or unusual hazards.
2.0

PURPOSE

The purpose is to identify the hazards associated with the work and eliminate or develop
control measures for each hazard. The reviews at each project stage focus on different
aspects, but the intent and the approach are consistent.
This guideline describes best practices for completion of Commissioning PHRs.
3.0

REFERENCE DOCUMENTATION

The following documents were used in the development of this document or are related to it.
The most recent revision shall be used. Also refer to the Project Navigator Toolkit
documents.
SPEC-02001
NAV-GP-0071-C
NAV-GE-0301
NAV-GP-0072-C
NAV-TP-0019-C
NOR 0052
NAV-TP-0070-C
4.0

Process Hazards Review - Requirements

FEL Stage PHR Guideline
Design PHR Guideline
Construction PHR Guideline
PHR Process Hazard Review Template
Health and Safety Systemic Requirements
Project Navigator RACI

COMMISSIONING PHRS

A Commissioning PHR must be done before doing any commissioning activities for the
project. The focus of this PHR is on the risks to the people doing the work, and others in the
area. Significant impacts to the operating equipment, the public or the environment caused
by the commissioning activities will also be examined.
One or more Commissioning PHRs are required for each major piece of equipment or
process system being commissioned. Major projects / work packages that involve many

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

08/23/2012

Revisit Date:

4/9
REV.

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

3
Trueman Hirschfeld

tasks or several different construction trades may require several separate Commissioning
PHRs to adequately assess all of the hazards and identify / develop control measures for
each. Specialty work may require a task-specific Commissioning PHR. These should focus
on actions of people, keeping in mind how they actually have to do the work.
If additional hazards are identified during the work the PHR must be revised and distributed
to all original PHR meeting participants. All affected workers must review and sign off the
revised PHR.
All personnel performing fieldwork activities related to the Engineering design and / or FEL
Studies (e.g. field measurements, sols investigation, General Review of Construction, etc)
must do a Construction PHR, or review the existing PHR documents related to the work.
Commissioning PHRs should be very specific as to the controls that are to be put into place.
These may include but are not limited to:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)

ZES tagging requirements:

Switchroom entry requirements
Requirements for work permits, hot-work permits
Confined space requirements:
Locations of safe assembly areas for emergency conditions (INVAC &
OUTVAC conditions)
Hygiene requirements for workers
Handling & disposal of hazardous materials
Noise limitations
The requirements for known heat stress or cold stress situations
Dust / Mist / Fume suppression & containment
Unusual PPE requirements
Project-specific procedures or new/unusual Area-specific procedures
Other issues identified during the SHE Review(s) done for the project
Temporary guarding / isolation requirements for commissioning

Where applicable, the Commissioning Safety Plan should incorporate all recommendations
from the Commissioning PHR.

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

4.1

08/23/2012

Revisit Date:

5/9
REV.

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

3
Trueman Hirschfeld

ATTENDEES

The Vale Lead will review the following list of potential attendees and invite the appropriate
personnel (for Project work the Vale Lead is the Project Manager or designate):
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)

the Project Manager and/or Project Engineer,

the projects Construction Manager,
the Project Safety Coordinator,
the Design Team Leader,
the Programmer / Designer
the Operations and Maintenance Representatives,
the local Safety Representative(s),
the local Health Representative(s),
the local Environmental Representative(s),
the local Joint Health & Safety Committee (JHSC) Rep(s),
one or more reps from the group(s) doing the work (contractors, consultants, or
Vale forces), and
Subject Matter Experts (SMEs) and other resource personnel as needed.

Representatives from the group managing the work (PMO or Plant) and from the group
performing the work must participate in all PHRs associated with the work.
5.0

PREPARATION FOR THE PHR MEETING

The Vale Lead will assign the meeting chairperson.

Where applicable, the meeting chairperson will review the SHE Review and previous PHR
reports prior to PHR meetings, to identify Action Items that need to be addressed, and to
develop a list of potential hazards.
Invitations to PHR meetings should be issued at least one week before the meeting, with the
following documents for review by participants, where applicable.
a)
b)
c)
d)

previous PHRs and SHE Reviews for this or similar work

the Scope(s) of the Work related to the items being commissioned
the sequence of commissioning tasks
a description of the equipment and processes / procedures to be used

These items must also be reviewed with the PHR team before assessing the hazards. It is
crucial that the participants understand the scope and the execution plan for the work being
done. Photos, Plot-plan or General Arrangement drawings and P&IDs are useful aids.

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

6.0

08/23/2012

Revisit Date:

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

6/9
REV.

3
Trueman Hirschfeld

USE OF THE PHR TEMPLATE (NAV-TP-0019-C)

The Vale Lead will determine who will record and publish the meeting minutes and
associated information, following the guidelines below.
6.1

METHODOLOGY TAB

The Overview of Scope should describe what the job entails and its boundaries. Include
sufficient detail to assess the hazards associated with the work. Expand on this at the
meeting as needed.
Under Methodology list the Commissioning tasks in sequence, including any unusual
circumstances (e.g. safety devices bypassed, automated equipment operated in manual
mode, etc)
Attach all relevant documentation e.g. Commissioning Checklist / Commissioning Plan,
Functional Specifications, Interlock lists, etc relating to the PHR.
6.2

GENERAL HAZARDS CHECKLIST TAB

The General Hazards Checklist is used to prompt discussions. Each hazard topic has an
embedded pop-up trigger that provides guidance and can prompt additional discussions.
6.3

PROCESS HAZARDS REVIEW MINUTES TAB

This tab is used to document the meeting discussions and to record the assignment of action
items.
Using What If questions, list events that could cause a hazardous condition or undesired
event to occur, and what the result might be (i.e. Injury/damage, etc). Ensure that the
What If statements are specific and completely describe the associated Hazard. (Do not use
single word What If statements.) List all of the What If statements (the possible events) for
the first Hazard, then move on to the next Hazard, and so on, until the PHR is completed and
agreed to by those in attendance.
In the Major/Minor column use major or minor to describe the risk rating.

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

08/23/2012

Revisit Date:

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

7/9
REV.

3
Trueman Hirschfeld

For each of the potential hazards listed, describe the Existing Protection in place that will
mitigate the hazard and lower the risk. List Recommendations that will further help mitigate
the hazards and lower the risk to ALARA. Use the Hierarchy of Controls model to generate
possibilities.

In the Action By column, assign the person / role responsible (c/w the company name) for
follow-up and mark the Status of the item as complete or incomplete. PHR action items may
be assigned to Vale personnel or to the contractor / consultant; both parties are ultimately
accountable for mitigation of the hazards identified.
All recommendations should be action statements that can be readily audited.
Example:

the Commissioning Lead will audit for compliance to standard ABC is

preferable to comply with standard ABC.

In the Action By column, assign the person / role responsible (c/w the company name) for
follow-up and mark the Status of the item as complete or incomplete. PHR action items may
be assigned to Vale personnel or to the contractor / consultant; both parties are ultimately
accountable for mitigation of the hazards identified.
Example:

John Smith, Vale or Jane Jones, ABC Contracting Inc., or Safety

Coordinator, XYZ Consultants, Ltd.

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

6.4

08/23/2012

Revisit Date:

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

8/9
REV.

3
Trueman Hirschfeld

WORKERS SIGN OFF SHEET

The Commissioning Checklist(s) and / or commissioning Plan, and the commissioning PHR
must be reviewed with every person assigned to the related tasks, Signatures are to be
obtained to document those reviews.
7.0

TYPICAL PHR MEETING AGENDA

Review the project background, the relevant scope(s) of work, and the commissioning
documentation to ensure that all attendees understand the commissioning process and its
intended outcomes.
Review the Process Hazard Review reports from the previous project stages, if applicable, to
ensure that any identified hazards have been addressed.
Perform a What-if / consequence analysis which will identify the hazards and formulate
recommendations.
Record the discussions and assign a person accountable for further action in eliminating or
managing the hazard.

Guideline
TITLE

VALE #

PAGE

NAV-GP-0073-C
PROJECT NAVIGATOR
TEMPLATES
COMMISSIONING PHR GUIDELINE
EffectiveDate:

8.0

08/23/2012

Revisit Date:

9/9
REV.

DM # 568692
Prepared By:

PHR Review
Committe

Approved By:

3
Trueman Hirschfeld

APPENDICES

Appendix A: Revision and Transition Notes

Appendix B: PHR Review Committee Members
Appendix A: Revision and Transition Notes
(Revisions are listed in reverse chronological order with most recent revision at the top.
Revision notes describe: what was changed, why it was changed, and the plan to implement
the change, including whether changes are retroactive)
Rev #

Date

Nature of
Change

2012/08/15

Document
Creation

2012/08/23

Formatting

Page inserted, replaced,

revised or cancelled

Approved by
document owner
PHR Review
Committee

Reformatting and wording to align

with other PHR Guidelines

Appendix B: PHR Review Committee Members

Chris Gordon Ops, Smelting / Refining
Shawn Laporte Mtce, Smelting / Refining
Mark Watson Ops, Mines / Mill
Jason Kilbride Ops, Production Services
Kelvin Hykawy Shops, Production Services
David Chisholm Shops, Production Services
Robert Siggelkow Shops, Production Services
Nancy Keller Safety & Health Systems, Sustainability
Trevor Rickwood Safety & Health Systems, Sustainability
Gary Remington Environment, Sustainability
Fred St. Jean Safety GSO, Sustainability
Darren Toner Safety GSO, Sustainability
Jim Mathiasen Safety GSO, Sustainability

Dylan Roberts Business Systems, Production Support

Trevor Ross CED/Project Systems, Production Support
Alan Delost CED, Production Support
Mike Fogarty CED, Production Support
Raphael Tiangco PMO Surface, Production Services
Trueman Hirschfeld PMO Surface, Production Services
Ivon Chaumont PMP PMO Surface, Prodn Services
Tom Gunn PMO Surface, Production Services
Tasha Pinkerton PMO Surface, Production Services
Maureen McKay PMO Surface, Production Services
Michael Danyluk PMO Surface, Production Services
Ed Kucyk PMO Mines/Mills, Production Services
Roch Vaillancourt PMO Mines/Mill, Production Services
Ron Pellerin PMO Mines/Mill, Production Services