Date Issued: January 2012 Revision Date: December 2012 Review Date: December 2015 Revision #

Transcription

1 SUNCOR ENERGY PRODUCTS DISTRIBUTION TERMINAL OPERATING MANUAL STANDARD OPERATING PROCEDURE MAINTENANCE TASKS Date Issued: January 2012 Revision Date: December 2012 Review Date: December 2015 Revision # PURPOSE This procedure provides the necessary information required to ensure that all Distribution Personnel are knowledgeable about the procedural and safety requirements that must be considered when installing a blind flange. 2.0 SCOPE This procedure applies to all Distribution Personnel, Contractors and Visitors who enter or perform work within any Suncor owned and operated Distribution Terminal. This procedure primarily applies to valves on piping and equipment in, adjacent to, or connected to processes that contain toxic, reactive, flammable, or explosive chemicals. 3.0 REFERENCED DOCUMENTS Distribution Standard Operating Procedure, Mechanical Isolation, SOP Cat A-1, SOP #03 Distribution Standard Operating Procedure, Work Permitting, Cat A-1, SOP #06 Distribution Standard Operating Procedure, Personal Protective Equipment, Distribution Procedure Program, Cat A-3, SOP # RESPONSIBILITIES Terminal Management; Accountable to ensure full implementation and compliance of this standard operating procedure. Installing a Blind Flange Page 1 of 7

2 Operating Authority; Responsible to ensure work permit is prepared and issued in accordance with Distribution SOP Cat A-1, SOP #06, Work Permitting. Responsible to ensure full compliance with this procedure. Responsible for safe and efficient execution of this procedure. Performing Authority; Responsible to comply permit conditions as prepared and issued in accordance with Distribution SOP Cat A-1, SOP #06, Work Permitting. Responsible to ensure full compliance with this procedure. Responsible for safe and efficient execution of this procedure. 5.0 PRECAUTIONARY STATEMENTS Training Proper training and demonstrated competency are prerequisites to performing this Standard Operating Procedure. Training shall be provided by a competent person and records shall be maintained Work Environment Hazards Slips or Trips Possible Position of Hands, Pinch Points Limited Access / Egress Foreign Bodies in Eyes Exposure to Hydrocarbons Ergonomic Hazards Awkward Body Position Walk Area Not Clear / Level Prolonged Twisting / Bending Motion Parts of Body in Line of Fire Installing a Blind Flange Page 2 of 7

3 Personal Limitations Distractions in Work Area Confusing instructions Fitness for Duty Personal Protective Equipment Personal protective equipment as outlined in Distribution Standard Operating Procedure, Cat A- 1, SOP #10 or as specified on the Safe Work Permit, dependent upon work to be completed as per job scope requirements. Special Personal Protective Equipment (PPE) To ensure eye/face protection from hazards associated with draining, venting or handling of irritant chemicals or hydrocarbons, approved chemical goggles and face shields may be worn, if required. An approved form of hearing protection shall be worn in areas of high noise potential to prevent overexposure which can result in hearing loss, if required. Special Tools and Equipment Personnel shall comply with Special Tools and Equipment in accordance with job requirements and permit. Should equipment isolation be required, isolation must be performed in accordance with Distribution Standard Operating Procedure for Mechanical Isolation, Cat A-1, SOP #03. Material Safety Data Sheet (MSDS) When hazardous materials are involved, Material Safety Data Sheets can be utilized as a reference for determining the extent of Personal Protective Equipment and other precautions. Installing a Blind Flange Page 3 of 7

4 CAUTION; When performing this procedure there is a potential for exposure to hazardous chemicals and/or hydrocarbons. Extreme caution should be exercised at all times. 6.0 SUSTAINMENT AND CONTINUAL IMPROVEMENT This document is classified in Process Safety terms as a Maintenance Task and as such must comply with the Maintenance Task Standard as outlined in Distribution Procedure Program, Cat A-3, SOP #01. National Terminal Maintenance Coordinator is to initiate document review process. To ensure this Standard Operating Procedure documents meets all applicable OEMS / PSM standards, this document is to be reviewed at a frequency not to exceed 3 years or when conditions change to warrant a review 7.0 PROCEDURE; Identify the need to close off end of line or access equipment inside line e.g., pump screen Determine what equipment, PPE, tools, and parts are required and available. Access and assemble tools, procedures and equipment. Following the Distribution Standard Operating Procedure for Mechanical Isolation, isolate, depressure and drain the line. Stand at the side of the flange and using two combination wrenches, loosen furthest bolts away from you on the flange. Installing a Blind Flange Page 4 of 7

5 Stand back to avoid injury. Any remaining pressure that may be in the line will escape out of this opening. Loosen and remove all bolts. Start with remaining back bolts, then bottom, then top. If needed, use a flange spreader to separate flanges. Remove old gasket. CAUTION! GASKET MAY CONTAIN ASBESTOS MATERIAL. Clean gasket material off flange faces with a sharp scraper. Apply anti seize compound to both ends of bolt stems. Insert bottom bolt through the blind flange. Roll flange into place and insert two side bolts. Slide a new gasket in between blind and open flange. Use bottom bolts as a cradle. Insert top bolt(s) and finger tighten. Fully tighten the bolts around flange squarely, using the crossover method. Tighten alternate and opposite bolts. Clean-up work area. Installing a Blind Flange Page 5 of 7

6 8.0 PROCEDURE DEVIATION Deviations from this standard operating procedure must be authorized using the Management of Change procedure. Deviations must be documented and documentation must include the relevant facts supporting the deviation decision Installing a Blind Flange Page 6 of 7

7 DATE AUTHOR DESCRIPTION REVISION January 2012 R. Rattray New document issue. Initial Issue December 2012 R. Rattray Re-Formatted for PSM Installing a Blind Flange Page 7 of 7