NORMAL OPERATING PROCEDURES Operating Parameter Information

Transcription

1 Operating Parameter Information Each operator performing the normal operating procedures (routine checks) of the facility should be familiar with the current normal operating parameters of all systems on the facility. This will enable the operator to identify when an adjustment or shutdown may be necessary. Some of the resources available to the Operator for this purpose include: Prior observations of parameters such as levels and temperatures The knowledge of others who are experienced with this facility A copy of the most recent Monthly Safety Devices Inspection and Maintenance Record (Monthly Testing Report) Safety Analysis and Function Evaluation (SAFE) Charts to identify safety device protected parameters When performing routine checks, operators should be able to evaluate all observable parameters to determine whether they are normal, troubleshooting is necessary or a shutdown is required. As the operator identifies that parameters are within normal ranges, no action is necessary. However, should the operator find that the parameter is beyond the normal range, but still within the safety device set point, troubleshooting could be required. The following list is a general overview of the preliminary actions an operator can take to determine the correct course of action for a parameter that has gone beyond the normal range but not yet reached the shutdown setting: An operator can monitor the parameter to see if it returns to normal. The outof-range parameter may be the result of a short-term fluctuation in incoming flow characteristics. (i.e. a momentary fluid surge) An operator can verify the settings of control loops/devices to verify they are set correctly. (i.e. a back-pressure valve setting may require adjustment) Once an operator has verified that the parameter is consistently outside the normal operating range as the result of an acceptable change in incoming flow characteristics, it may be necessary to establish a new normal operating range. An operator may seek the experience of other operators or supervisors in determining the cause for the abnormal parameter. An operator may determine it is necessary to perform shutdown procedures before the safety device setting if the parameter is increasing or decreasing at a rate too quickly to troubleshoot. Rev: 1 Date: 7/31/18 Page 1 of 16 WC 289 A

2 Parameters with unacceptable consequences for deviation are identified according to regulatory guidelines employed during the design process. Safety devices are installed in one or more components of the production train (process system) to prevent those deviations and their subsequent consequences. The following charts can be used to assist an operator in troubleshooting and correcting potential deviations before a shutdown is necessary. NOTICE: Safety devices are set to perform automatic shutdowns of the facility processes when the operating parameters go beyond the troubleshooting zone. Any operation of the facility while a parameter is beyond the troubleshooting zone is considered Emergency Operations. As stated in Section 1, the facility will not be operated under emergency conditions. Any operator finding a parameter beyond the safety device setting should assume that the safety device has failed and immediately initiate a shutdown of the system or, if necessary, the entire facility process. Rev: 1 Date: 7/31/18 Page 2 of 16 WC 289 A

3 PRESSURE: Causes for higher than normal pressure: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Equipment Malfunction Obstruction or restriction downstream Gas Blow-by upstream Inflow exceeds outflow Liquid overflow through gas outlet Return variable to normal Manually shutdown vessel Repair, replace or adjust equipment Remove obstruction or restriction; check position of valves Decrease temperature Vessel may over-pressure and rupture Equipment may fail Liquids may spill Hydrocarbons may reach ignition source Gas may release into atmosphere Personnel may be injured Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Implement Emergency Response Plan Thermal expansion Causes for lower than normal pressure: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Equipment Malfunction Obstruction or restriction upstream Leak Gas Blow-by Outflow exceed inflow Thermal contraction Return variable to normal Manually shutdown vessel Repair, replace or adjust equipment Remove obstruction or restriction; check position of valves Isolate leak Increase temperature Liquids may spill Hydrocarbons may reach ignition source Gas may release into atmosphere Personnel may be injured Backflow may occur Collapse of component Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Implement Emergency Response Plan Rev: 1 Date: 7/31/18 Page 3 of 16 WC 289 A

4 LEVEL: Causes for higher than normal liquid level: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Equipment Malfunction Obstruction or restriction upstream Liquid input exceeds liquid output Return variable to normal Manually shutdown vessel Repair, replace or adjust equipment Remove obstruction or restriction; check position of valves Liquids overflow to downstream component Liquids may spill Hydrocarbons may reach ignition source Vessel overpressures Personnel may be injured Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Implement Emergency Response Plan Causes for lower than normal liquid level: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Opening bypass valve around control valve Equipment malfunction Leak Return variable to normal Manually shutdown vessel Repair, replace or adjust equipment Close bypass valve Liquids may spill Overpressure in downstream component Hydrocarbons may reach ignition source Gas may release into atmosphere Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Isolate leak Personnel may be injured Implement Emergency Response Plan Rev: 1 Date: 7/31/18 Page 4 of 16 WC 289 A

5 TEMPERATURE or LEAK: Causes for higher than normal temperature: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Equipment malfunction Malfunction of fuel system equipment Ignition of medium leaking into firing chamber Obstruction or restriction Manually shutdown vessel Repair, replace or adjust equipment Remove obstruction or restriction; check position of valves Reduce heat input Increase liquid level Vessel may over-pressure and rupture Equipment may fail Liquids may spill Hydrocarbons may ignite Gas may release into atmosphere Personnel may be injured Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Implement Emergency Response Plan Excess heat input Low liquid level Causes for a leak: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Equipment malfunction Deterioration of construction material Accidental damage Rupture Manually shutdown vessel Repair, replace or adjust equipment Isolate leak Liquids may spill Hydrocarbons may reach ignition source Gas may be released into atmosphere Personnel may be injured Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Implement Emergency Response Plan Rev: 1 Date: 7/31/18 Page 5 of 16 WC 289 A

6 IGNITION SOURCES: Causes for direct ignition sources: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Malfunction of ignition equipment Fuel in air intake Emission from stack Liquid carry-over in gas burner Direct flame Reverse draft Manually shutdown vessel Manually shut off fuel supply Repair, replace or adjust ignition system Extinguish flames Eliminate fuel source Eliminate draft Ignition sources may reach flammables and cause fire Increase temperature Liquids may spill Gas may be released into atmosphere Personnel may be injured Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Implement Emergency Response Plan Causes for combustible vapors in a firing chamber: Steps to avoid or correct deviation before it reaches the shutdown setting: Consequence as a result of parameter not being corrected if the safety system fails: Precautions to prevent exposure or damage and control measures to take if exposure occurs: Equipment malfunction Flame failure Improper operating procedures Manually shutdown vessel Ventilate chamber Repair, replace or adjust equipment Correct operating procedures Combustible vapors may reach ignition source and cause fire Carbon build-up may occur Vessel may rupture Personnel may be injured Wear proper PPE Train personnel Refer to SDS and respond accordingly Administer first-aid/cpr Activate ESD Implement Emergency Response Plan Rev: 1 Date: 7/31/18 Page 6 of 16 WC 289 A

7 C. INCOMING PIPELINES SECTION 5 1. Perform routine inspections of incoming pipelines Incoming Pipeline from WC 290, KAQ-0290 a. Verify operating pressure are within normal operating ranges b. Inspect pipeline from riser at waterline to separator or header for leaks c. Ensure TSE (fusible loop) is properly positioned and secured at receiver (if applicable) d. Verify that the SDV is completely open e. Conduct pollution inspections daily 2. Perform routine inspections of incoming pipeline safety systems a. Verify there are no bypassed devices on the Master Panel for in service process components Rev: 1 Date: 7/31/18 Page 7 of 16 WC 289 A

8 D. SEPARATION SYSTEM 1. Perform routine inspection of the pressure vessels #1 Separator, MBD-0100 #3 Separator, MBD-0120 a. Verify operating pressures are within normal operating ranges b. Visually inspect pressure controllers and control valves to ensure they are properly maintaining system pressures c. Verify all liquid levels are within normal operating ranges d. Visually inspect all liquid level controllers and dump valves to ensure they are properly maintaining liquid levels e. Verify all manual outlet valves are correctly positioned to direct flow to the correct downstream components f. Verify that PSV isolation valves are locked open g. Verify that safety devices appear in proper working order h. Verify TSE (fusible loop) is properly positioned and secured i. Perform visual inspection of each vessel for leaks 2. Perform routine inspections of Master Control Panel a. Verify panel pressures are within normal operating ranges b. Verify there are no bypassed devices on the panels for in service process components c. Verify bypassed devices for OOS equipment are properly tagged d. Perform visual inspection of each panel for leaks e. Perform visual inspection of each panel for exposed or unsecured wiring Rev: 1 Date: 7/31/18 Page 8 of 16 WC 289 A

9 F. WATER HANDLING SYSTEM 1. Perform routine inspection of the pressure vessels Skimmer, MBM-0200 a. Verify all liquid levels are within normal operating ranges b. Visually inspect all liquid level controllers and dump valves to ensure they are properly maintaining liquid levels c. Visually inspect blanket gas pressure control valves to ensure they are properly maintaining blanket gas pressure d. Verify all manual outlet valves are correctly positioned to direct flow to the correct downstream components e. Ensure Overboard Water Inspections have been performed f. Inspect Flotation Cell Skid components Ensure proper operation of agitator motors Ensure proper operation of skimmer motors g. Verify that PSV isolation valves are locked open h. Verify that safety devices appear in proper working order i. Verify TSE (fusible loop) is properly positioned and secured j. Perform visual inspection of each vessel for leaks 2. Perform routine inspection of the pumps Skimmer Pump, PBA-0210 a. Verify all manual valves are correctly positioned to allow suction and discharge flow to/from the pumps b. Verify all discharge pressures are within normal operating ranges when pumps are running c. Visually inspect electric motors for any observable problems d. Verify that PSV isolation valves are locked open e. Verify that safety devices appear in proper working order f. Verify TSE (fusible loop) is properly positioned and secured g. Perform visual inspection of each pump for leaks Rev: 1 Date: 7/31/18 Page 9 of 16 WC 289 A

10 G. GAS COMPRESSOR Compressor, CBA 4120: 1. Perform routine inspection of the pressure vessels Suction #1 Scrubber, MBF st Stage, CBA 1600 Suction #2 Scrubber, MBF nd Stage, CBA-1620 a. Verify operating pressures are within normal operating ranges b. Verify all liquid levels are within normal operating ranges c. Visually inspect all liquid level controllers and dump valves to ensure they are properly maintaining liquid levels d. Verify all manual outlet valves are correctly positioned to direct flow to the correct downstream components e. Verify that PSV isolation valves are locked open f. Verify that safety devices appear in proper working order g. Verify TSE (fusible loop) is properly positioned and secured h. Perform visual inspection of each vessel for leaks 2. Perform routine inspection of the coolers First Stage Cooler Second Stage Cooler a. Verify operating temperatures are within normal operating ranges b. Verify TSE (fusible loop) is properly positioned and secured c. Perform visual inspection of each cooler for leaks Rev: 1 Date: 7/31/18 Page 10 of 16 WC 289 A

11 3. Perform routine inspection of the compressor cylinders 1 st Stage Gas Compressor 2 nd Stage Gas Compressor a. Visually inspect compressor lube oil systems to ensure they are operating properly (as applicable) b. Verify that each stage discharge temperature is within normal operating range c. Verify that each stage discharge pressure is within normal operating range d. Verify that PSV isolation valves are locked open e. Verify BDVs are completely closed when compressors are running f. Visually inspect all recycle controllers and control valves to ensure they are operating properly g. Verify that safety devices appear in proper working order h. Verify TSE (fusible loop) is properly positioned and secured i. Perform visual inspection of each compressor for leaks j. Perform visual inspection of components and piping for abnormal or excessive vibration. 4. Perform routine inspections of control panels Local Compressor Panel a. Verify panel pressures are within normal operating ranges b. Verify there are no bypassed devices on the panels for in service process components c. Verify bypassed devices for OOS equipment are properly tagged d. Perform visual inspection of each panel for leaks e. Perform visual inspection of each panel for exposed or unsecured wiring Rev: 1 Date: 7/31/18 Page 11 of 16 WC 289 A

12 K. DEPARTING PIPELINES 1. Perform routine inspections of all departing and bidirectional pipelines 8 Departing Pipeline, KAH-0270 a. Verify operating pressure are within normal operating ranges b. Inspect pipeline from process component outlets to the riser at waterline for leaks c. Ensure TSE (fusible loop) is properly positioned and secured at receiver (if applicable) d. Verify that the SDV is completely open (as applicable) e. Conduct pollution inspections daily Rev: 1 Date: 7/31/18 Page 12 of 16 WC 289 A

13 M. FUEL GAS SYSTEM 1. Perform routine inspection of the pressure vessels SECTION 5 Fuel Gas Scrubber, MBF-0150 Fuel Gas Scrubber, MBF-0160 a. Verify operating pressures are within normal operating ranges b. Visually inspect pressure controllers and control valves to ensure they are properly maintaining system pressures at each pressure cut c. Verify all liquid levels are within normal operating ranges d. Visually inspect all liquid level controllers and dump valves to ensure they are properly maintaining liquid levels e. Verify all manual outlet valves are correctly positioned to direct flow to the correct downstream components f. Verify that PSV isolation valves are locked open g. Verify that safety devices appear in proper working order h. Verify TSE (fusible loop) is properly positioned and secured i. Perform visual inspection of each vessel for leaks Rev: 1 Date: 7/31/18 Page 13 of 16 WC 289 A

14 R. CHEMICAL INJECTION SYSTEM NOTE: Proper Personal Protection Equipment (PPE) must be worn when performing procedures involving chemicals. Refer to the SDS for additional information on proper PPE required for handling each chemical. 1. Perform routine inspections of any installed chemical systems: Refer to the Chemical Inventory for a current list of chemicals and the corresponding injection/treatment information a. Check the level of chemical in the storage tank b. Verify all injection lines are installed using stainless steel tubing (no high pressure hoses, including stainless steel, should be used). c. Verify that all injection line tubing and valves are rated equal to or higher than the Maximum Working Pressure of the injection point. d. Verify a FSV is installed in the injection line at the injection point. e. Perform visual inspection of each system from tank discharge to pump suction, and along the pump discharge to the injection point for leaks f. Verify the injection rates are set according to the recommendation of the vendor or company specifications g. Perform visual inspection of each pump for exposed or unsecured wiring and/or any observable problems Rev: 1 Date: 7/31/18 Page 14 of 16 WC 289 A

15 S. SUMP SYSTEM SECTION 5 1. Perform routine inspection of the sump tank Sump Tank, ABH-0220 a. Verify all liquid levels are within normal operating ranges b. Visually inspect all liquid level controllers and pump control valves to ensure they are properly maintaining liquid levels c. It is advisable to occasionally manually activate the pump run signal to ensure pump functionality d. Visually inspect Vents, PVSVs and PSVs to ensure they appear to be in proper working order e. Verify that safety devices appear in proper working order f. Verify TSE (fusible loop) is properly positioned and secured g. Perform visual inspection of each tank for leaks h. Perform a visual inspection of all curbs and gutters throughout the facility 2. Perform routine inspection of the pump Sump Pump, PBH-0230 a. Verify all manual valves are correctly positioned to allow suction and discharge flow to/from the pump b. Verify discharge pressures are within normal operating ranges when pumps are running c. Verify that PSV isolation valves are locked open d. Verify that safety devices appear in proper working order e. Visually inspect electric motors for any observable problems f. Verify TSE (fusible loop) is properly positioned and secured g. Perform visual inspection of each pump for leaks Rev: 1 Date: 7/31/18 Page 15 of 16 WC 289 A

16 T. FLARE SYSTEM 1. Perform routine inspection of the flare scrubbers Vent Scrubber, MBF-0230 a. Verify all liquid levels are within normal operating ranges b. Visually inspect all liquid level controllers and pump control valves/dump valves to ensure they are properly maintaining liquid levels c. It is advisable to occasionally manually activate the pump run signal to ensure pump functionality d. Visually inspect Vents, PSVs and PSEs to ensure they appear to be in proper working order e. Verify that safety devices appear in proper working order f. Verify TSE (fusible loop) is properly positioned and secured g. Perform visual inspection of each vessel for leaks 2. Perform routine inspection of the pumps Scrubber Pump, PBA-0250 a. Verify all manual valves are correctly positioned to allow suction and discharge flow to/from the pump b. Verify discharge pressures are within normal operating ranges when pumps are running c. Verify that PSV isolation valves are locked open d. Verify that safety devices appear in proper working order e. Visually inspect electric motors for any observable problems f. Verify TSE (fusible loop) is properly positioned and secured g. Perform visual inspection of each pump for leaks Rev: 1 Date: 7/31/18 Page 16 of 16 WC 289 A