Veriforce TG CCT 609OP. Training Guide

Transcription

1 Training Guide Directions: This training guide is to be used by a Veriforce Authorized Evaluator/Trainer and Trainee during on-thejob training (OJT) or prior to an evaluation as a resource. (S) Indicates a demonstration or skill task; (K) indicates a knowledge task. OJT Reminder: OJT is an active hands-on process. Practice should be as similar to the actual job task as possible. However, if the training is being provided on an actual job site while a covered task is actually being performed, the Evaluator either needs to be qualified on that covered task or be assisted by someone who is qualified on the covered task. The Evaluator should closely monitor the Trainee's practices to ensure safe and correct task performance. At no time should a non-qualified individual perform, or train for, a covered task unless directed and observed by a qualified individual. However, if the span of control for that particular covered task is 1:0 (requiring only qualified individuals to perform the covered task), the training must be simulated. Training is simulated by "walking through" the task and simulating all actual manipulations (valves, switches, tools, etc.) an individual would use during the performance of a covered task. Simulating includes the use of safety and administrative requirements as if the task were being performed live. Refer to the Veriforce Evaluator Training Program for more on how to conduct formal OJT. Disclaimer: This training resource is offered in good faith. Anyone choosing to utilize or rely on this training resource is doing so at their own discretion, risk and choice. Although every attempt has been made by Veriforce, LLC (the Company ) to ensure the correctness and suitability of this document and to correct any errors brought to the attention of the Company, the Company makes no representation or warranty regarding correctness or suitability (either directly or indirectly) of information referenced or implied within this training resource. In no event shall the Company be liable for any damages (including, but not limited to, special, incidental or consequential damages) whatsoever (including, but not limited to, death, personal injury, damage to person or property, loss of use, and/or loss of revenues), whether in an action of contract, negligence, or other action, arising out of or in any way associated with the use or misuse of this document. All critical information should be independently verified by the user and the user shall not rely on the contents provided herein without such independent verification. The subject matter included in this training has been compiled from a variety of sources and is subject to change without notice. The Company reserves the right to add, remove and alter information contained in this document without notice. The Company may provide links to other sites for your convenience; however, the Company takes no responsibility and makes no representation or warranty regarding the accuracy or currency of information contained within such sites. The Company does not endorse any information, goods, or services referred to within such sites, and the provision of links by the Company shall not be interpreted to be an endorsement of such information, goods or services. The content of this training resource is provided for personal use only, and all other use, copying or reproduction of this training or website or any part of it is prohibited. CCT: 609OP Inspect and Maintain Odorization Equipment Page 1 of 6 Copyright 2013 Veriforce, LLC. All rights reserved. 06/5/2014

2 Recommended Student Training or Resources: Recommended Student Training or Resources: DOT 49 CFR (e) Odorant Systems Every day, billions of cubic feet of natural gas are transported from where they are gathered to the consumer. While many forms of transportation are used to transport/distribute product to marketplaces, pipelines remain the safest, most efficient, and most economical method of transportation. The vast majority of the 2.5 million miles of pipelines used to transport and distribute natural gas within the US are buried safely below the ground. However, even though these pipes are buried, the possibility of a leak remains. Because natural gas is colorless and odorless, gas companies add odorant to aid in the discovery of a leak. All distribution lines must be odorized. Transmission lines that meet certain criteria must also be odorized. Operators do not simply open a valve and dump odorants in their lines; they use odorizing systems that add the odorant compounds in a controlled and effective manner. This equipment requires regular inspection and maintenance to ensure proper working order. Knowledge Describe the purpose of odorant systems. Natural gas by itself has no odor; in fact, what most people consider a gas smell is actually the mercaptan compound that is added to the gas. Since odorants are organic sulfur compounds, they have a very strong rotten egg smell. There are a variety of odorant blends, methods, and equipment used to odorize natural gas lines. For more information on Odorant blends refer to the online training module. Odoriziation methods and equipment will be discussed later. For now, let s focus on the purpose of odorizing gas lines. When thinking of why operators have to add odorants to their gas lines, you should think of two reasons. First, odorization adds a level of safety and security to the gas system by providing a warning for the public so that leaks can be more readily detected. Odorants are organic sulfur compounds which produce a very strong gas or rotten egg smell. Secondly, Department of Transportation (DOT) regulations require all distribution gas pipelines to be odorized. There are also requirements for some transmission lines to be odorized depending on the line s location. In other words, odorant systems are required by regulation in certain locations so that leaks can be more Page 2 of 6 Copyright 2013 Veriforce, LLC. All rights reserved. 06/5/2014

3 readily detected. According to DOT regulation , all distribution lines that contain combustible gases are required to be odorized, no matter their location. Furthermore, the line must be odorized to the point that gas could be detected by a person with a normal sense of smell at 1% volume of gas in air (1/5 lower explosive level). 1/5 LEL The LEL (lower explosive limit) of a flammable gas is the minimum concentration of that gas at which it will burn at normal ambient conditions if there is a source of ignition (e.g., arc, flame) present. The LEL standard for natural gas is 5% by volume of gas in air. DOT regulation also specifies times when transmission lines require odorization. These times are when the transmission line passes through class 3 and class 4 locations. The regulation does provide for some exceptions to odorizing requirements. For more information on Pipeline Class Locations and Exceptions to Transmission Line Requirements refer to the online training module. Odorization is an important aspect to gas safety and is required by the DOT. Always remember that odorant systems are required by regulation in certain locations so that leaks can be more readily detected. Knowledge Identify common types of odorization equipment. Knowing that gas is odorless and that regulations require certain gas lines to be odorized, operators must use equipment to introduce the odorants into the gas line. Odorants are added to gas lines through one of these methods. Injection pump odorizer Non-injection type odorizer Injection Pump Odorizer This type of odorizer method uses a pump with an electronic output signal proportional to gas flow for the injection of odorant into the mainline and laterals. In other words, it directly injects a controlled amount of odorant into the gas flow according to the volume of gas passing through the pipeline. Non-Injection Type Odorizer The other way of odorization is through the non-injection method of absorption or vaporization. This noninjection method is accomplished through two types of equipment systems. Wick Or bypass Wick The wick type odorizer is based on evaporation of the odorant as the natural gas flows by a wick that which is in contact with a reservoir of odorant. Through a wicking effect, the odorant is transferred from the reservoir to the gas stream, and the amount of odorant absorbed into the gas stream is directly Page 3 of 6 Copyright 2013 Veriforce, LLC. All rights reserved. 06/5/2014

4 proportional to the gas flow. Bypass The bypass type of odorizer operates similarly to the wick system except, the gas contacts the odorant reservoir directly. Bypassing a portion of the total gas stream through the odorant reservoir controls the rate of odorization. The odorization of natural gas is accomplished through the use of equipment such as injection pumps, wick systems, and bypass systems. The use of any of these systems will require some attention and maintenance. Skill Demonstrate how to inspect odorization equipment. No matter which odorization equipment system is used, inspection and maintenance play an important part in the effectiveness of any odorization program. The equipment used to odorize will vary depending on the manufacturer and geographical location. Always refer to your equipment s manufacturer s instructions on how to perform inspections and maintenance. DOT regulation (a) requires odorization to the point where the gas can be detected by a person with a normal sense of smell at a concentration of gas in air that is one-fifth of the lower explosive limit(lel). This means that someone could smell natural gas, in reality the odorant, at a gas concentration of 1% in air (5% being the LEL of natural gas). In order to determine if the odorization level is up to regulation, operators are required to take periodic samples. This should be part of any odorization system s inspection and maintenance program. Operators can use any instrument that is capable of determining the percentage of gas in air at which the odor becomes readily detectable. Operators may also use chemical analysis or an odor concentration meter to measure the odorization concentration in a gas stream. When using instruments, ensure that sample lines and the instrument are clear of any previous gases tested and are calibrated according to manufacturer s guidelines. If performing a sniff test, ensure the air is free of odors and drafts before starting. The procedure listed here outlines the steps involved in inspecting odorization equipment, not the specific method of inspection (such as what the proper odorant level should be). Remember that there are many models and types of odorization systems, so always refer to the equipment's specific manufacturer s guide for its specific method of inspection and maintenance. The steps to inspecting odorization equipment consist of the following: Visually inspect fittings, connections, and odorization equipment for defects. Determine the odorant level Calculate the injection rate for flow conditions and make necessary adjustments Repair/replace equipment, as necessary. Fill the odorant tank Visually inspect fittings, connections, and odorization equipment for defects. While you approach the odorizing equipment, conduct a visual inspection. Make sure that the equipment Page 4 of 6 Copyright 2013 Veriforce, LLC. All rights reserved. 06/5/2014

5 and its connections and fittings are free of defects or damage. Look for loose connections and leaks. Examples of leaks could include build up of moisture, dirt, moist dirt, or a discolored area. Some areas to visually inspect may include: Odorant pumps Injection systems Odorant tanks Fittings and connections Determine odorant level Gauge what the present odorant level is, and determine if it is enough to achieve the proper amount of odorization according to the gas flow. Some odorizers come equipped with injection rate meters or sight glasses so the operator can monitor odorant levels. Calculate injection rate for flow conditions and make necessary adjustments Rate of flow may change according to customer needs, seasons, or supply. It is necessary to re-calculate and adjust odorization rate according to changes in gas flow. Repair/replace equipment, as necessary. Repair and replace parts and components as needed. Refer to the manufacturer s guidelines for model specific replacement parts and repair procedures. Fill odorant Each type of odorizing system will be filled differently. Prior to filling the system with odorant, always refer to the system's manufacturer s guidelines, the odorant s safety data sheet (SDS), and company safety procedures. No matter the type of odorization system you have to fill, the following are certain things you should take into consideration. Wear personnel protective equipment (PPE) Check the wind direction Eliminate all ignition sources Isolate the system De-pressurize the tank Fill according to procedures Record the amount of odorant used Close the system from the atmosphere Return the system to use Page 5 of 6 Copyright 2013 Veriforce, LLC. All rights reserved. 06/5/2014

6 Abnormal Operating Conditions (AOCs) You are required to possess the ability to RECOGNIZE and REACT to the listed AOCs for each task. Be prepared to answer questions concerning additional AOCs that may be relevant. Evaluators may ask questions about AOCs throughout the evaluation. An AOC is defined in 49 CFR and as: A condition identified by the operator that may indicate a malfunction of a component or deviation from normal operations that may: Indicate a condition exceeding design limits; or Result in a hazard(s) to persons, property, or the environment. Recognize: Unintentional releases, vapors, or hazardous atmosphere could be signs that an abnormal operating condition has occurred. Examples could include, but are not limited to, unexpected odor, blowing gas, and shimmering air. AOC AOC React/Respond: Proper reactions/responses to take in the event of an unintentional release, vapors, or hazardous atmosphere include the following: Recognize: Eliminate potential ignition sources Move to a safe location Notify emergency response personnel, as appropriate Limit access to location, as necessary Follow appropriate procedures for notification, documentation, and remedial action Failure, malfunction, or damage to odorizer equipment is an abnormal operating condition. Examples could include, but not limited to, odorizer pump not working properly (i.e. vapor lock, improper injection amount), damage seals, leak in odorize system, damaged injection probe fitting, tubing damage, and tank damage/corrosion. React/Respond: Proper reactions/responses to take in the event of a failure, malfunction, or damage to odorizer equipment include the following: Determine extent, cause and potential hazard(s) of failure and/or malfunction Follow appropriate procedures for notification, documentation, and remedial action Page 6 of 6 Copyright 2013 Veriforce, LLC. All rights reserved. 06/5/2014