Veriforce TG CCT 661OP. 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: 661OP Launching and/or Receiving Internal Devices (Pigs) Page 1 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

2 Recommended Student Training or Resources: Recommended Student Training or Resources: DOT 49 CFR DOT 49 CFR (d)(5)(iv) DOT 49 CFR (d)(9) DOT 49 CFR (c) DOT 49 CFR Internal Devices (Pigs) Internal devices also known as pigs are used to preform several maintenance tasks to the pipeline. These tasks can take place during pipeline construction to pipeline decommission. Some of the tasks include: Clean the inside of the pipeline Conduct maintenance Separate product (batching) Remove blockages inside the pipeline Before a pig can be introduced into a line, there are certain steps that need to be followed. Pipelines are often operating at high pressures and can pose serious hazards if an pig is introduced or removed incorrectly. Your ability to properly perform this task will help maintain the integrity of the pipeline and, more importantly, the safety of you and your co-workers. Knowledge Explain what is required prior to performing task. Prior to performing this task, you will need the: Pipeline operator-approved procedures for the specific site Appropriate equipment/materials needed Type of pig needed to preform the operator specific task Pipeline Operator-Approved Procedures The Operator will develop site-specific procedures for each pigging site. The procedure will typically include: The normal procedure for launching and receiving Safety concerns of the site. The Normal Procedure for Launching and Receiving Procedures will vary from Operator to Operator, but the majority of procedures will include information such as launcher or receiver layout, diagrams, and the sequence of valves for launching and receiving. Page 2 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

3 Safety Concerns of the Site The Operator s procedure could also address safety concerns that must be addressed before performing the task, such as the type of product in the line as well as the site specific hazards that might be seen on the site. Perhaps the most important condition that must be maintained is the flow on the pipeline. A blockage can cause over pressure that could result in rupture. Some other safety concerns include, but are not limited to: Venting or releasing of product Actions to take for a stuck pig Proper procedures should be followed for venting or draining of explosive gases. Should you have any questions regarding the Operator procedure and safety concerns, please notify your supervisor or operator representative. Appropriate Equipment/Materials When performing pigging operations, it is important that only the appropriate equipment or materials are used in the process. Each site will have specific instructions on how the work should be performed. Factors that could affect the equipment or material needed could be: The type of product in the pipeline What will be used to propel the pig, such as: product flow compressed air or nitrogen Depending on the size of the pig being launched, special equipment might be required to load and launch. Device (Scraper, Sphere, Brush) To perform this task, you will need a pig. There are many types of pigs and each type has a different use. Some of the most common types include: Scraper which is used to scrape the inside walls of the pipeline to remove debris, left over product, or built-up material. Sphere - which can be of a solid construction or filled with glycol or water. Brush which is used for light to medium cleaning of the pipeline. ILI (In-line inspection tools), also known as smart pigs, - which can be used to provide information on the internal condition of the pipe. Make sure to compare the information that you received in the pipeline diagram to the pig manufacturer specifications. Page 3 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

4 Tools, Gaskets, Pressure Gauges, Gas Monitors Veriforce TG CCT 661OP In addition to the pig, you will also need a variety of tools and equipment. These include, but are not limited to: Pipe wrenches Gaskets Pressure gauges Gas monitors Fire fighting equipment Personal Protective Equipment (PPE) Forklift or crane Waste recovery equipment Hydraulic rams or winches Knowledge Explain how to verify the condition of the device to be launched. Prior to performing this task, you will need to verify the condition of the pig to be launched. This is done to make sure the size, type, material, and condition of the pig meet operator requirements. You can determine the correct pig to use through the following process. Size Inspect the pig for correct sizing. The size of the pig should not be more than 90 percent of the diameter of the smallest part of the pipeline that is to be pigged. This includes all valves and bends. A pipe diagram should be obtained through the pipeline operator that shows the size of the bends in the pipeline. Compare the information that you received in the pipeline diagram to the pig manufacturer s specifications. If there are valves that reduce or restrict the pipeline, it is possible the line is not able to be pigged. Type Next, you should check that the pig is the correct type. The type of pig will depend on the operation that the Operator has requested to be completed. Examples include: Cleaning Inspecting Drying Batching Using the correct pig is important. Using the wrong pig can damage the pig, the pipeline, or cause the pig Page 4 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

5 to become stuck in the pipeline. Material The material the pig is constructed of is also an important factor to consider. Some of the common materials include: Gel Polyurethane Foam When deciding what pig to use make sure it works with what is flowing through the pipe. Doing this will avoid damaging the pig or affecting the product flowing through the pipe. Before launching any pig, you should check the body of the pig to be launched and ensure that it is in good condition and has no broken parts or excessive wear. Refer to your Operator s guidelines to verify the type of pig that is needed. Knowledge Launcher and Receiver Components Main Pipeline Valve The main pipeline valve is used to isolate the pig launcher from the mainline. Main Bypass Valve The main bypass valve is used to redirect the flow around the pig launcher. Bypass Valve The bypass valve can be used to move the flow from in front of the pig to behind the pig. This can also be known as a bridal valve. Page 5 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

6 Drain Valve The drain valve or sump is used to remove any type of liquid from the line. It typically connects to a recovery unit that collects the drained liquid. Blowdown Valve The blow down valve is used to remove any pressure from the isolated part of the line. Some launchers may have more than one blow down valve. Main Line Blowdown Valve The main line blow down valve may be used to lower the pressure on the receiver end to allow the pig to arrive at the receiver. Closure Door The closure door is the entry and exit point for the pig. There are several different types of closures. Two common types you might see are the hinged type and the screw type. Pressure Indicator The Pressure Indicator can be any type of device that visually shows you that pressure still remains on the pipe. It may consist of: Digital pressure gauges Manual pressure gauges Barrel Closure pressure alert valve (also known as a tattle tale) The Barrel is the larger part of the launcher. The added space provides the room needed to easily load and remove the pig from the launcher. The barrel runs from the launcher closure to the reducer. Thermal Relief Valve The Thermal Relief Valve works just like a normal relief valve but operates off temperature. If the temperature rises above the preset temperature, the valve opens, removing the pressure. Reducer The Reducer brings the size of the pipe from the launcher to the normal size of the pipe. Pup A Pup is a short length of pipe that is used in between the valve and the end of the launcher. The real use for a Pup is to spread out the heat-affected zone from welding the pipeline together. Pig Signal Indicator A Pig Signal Indicator is a manual device that can be attached to the pig launcher that will notify you once the pig has passed the signal. Note: If a manual pig sig is not attached to the launcher or receiver, you may need to listen or feel the vibration to track the pig as it is launched or received. Page 6 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

7 Vent Valve Veriforce TG CCT 661OP Note: Refer to your Operator-specific guidelines for the type of method used to track the pig being launched or received. The Vent Valve may be present on some units to allow a second place to vent the pressure from the receiver. This second valve will show you that no pressure is built up behind the pig in the receiver. Barred Tee The Barred Tee is used inside the pipeline to ensure that the pig does not go the wrong way in the pipeline. Skill Demonstrate how to perform a launching operation. Now, that you have read bit about what the pig does for the pipeline, let s talk about how to perform a launching operation. Note: The process that we are discussing is for a specific site. Each site may have different process steps or different equipment. Before conducting pigging operations, refer to your Operator s site specific procedures and review the piping diagram. First, take a look at your site. Ensure that all necessary personal protective equipment (PPE) is available and properly worn. PPE requirements may differ for each location; therefore, follow Operator guidelines. As soon as you are on site, begin to monitor the atmosphere with gas monitors to ensure that there are no explosive conditions present. Monitoring will continue until you are finished and leave the site. Also, look around for any visual safety issues or physical defects on the pipeline. The launcher area should be free of any extra materials that will not be used in the process. Once you are sure you have a hazard-free work site, the next step is to perform the launching operation. The following steps will be used to perform the launching operation: Identify and locate associated valves for launching operation Ensure valves function correctly and are operated in the proper sequence for launching phases Remove the product/gas from the launcher and associated isolated piping Ensure that no pressure exists in the barrel before opening the barrel door Verify the pig is loaded correctly Purge and/or pressurize the piping in preparation for launching Place valves in correct position for launching the pig and launch into the piping system Verify all identified valves are realigned for normal configuration Identify and locate associated valves for launching operation. Start by identifying the associated valves for the launching operation. The site diagram you received from the operator should tell you the correct valves in the order in which they need to be operated. If no pipeline diagram is available, contact your Operator representative for assistance. This is necessary because every site may be setup differently. Page 7 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

8 Ensure valves function correctly and are operated in the proper sequence for launching phases. When preparing for a launching operation the main objective is to maintain the flow at all times. If the flow is not maintained, the over pressure could cause injury or damage to the pipeline. Over pressure can be prevented by ensuring the valves function correctly and are operated in proper sequence for launching phases. A method recommend by best practices is that a dry run of the operation be conducted before working on an active pipeline. The dry run should cover the process step by step as well as emergency procedures that the workers may need to perform. The valves that will be used in the process should be tested prior to conducting the launch operation to ensure they open and close fully. Remove the product/gas from the launcher and associated isolated piping. Once you have located and closed the correct valves to isolate the launcher, the pressure will have to be removed from the launcher. Note: DO NOT STAND DIRECTLY IN FRONT OF THE LAUNCHER OR RECEIVER CLOSURE DOOR. Pressure can build up behind a blockage, and once the blockage is removed, the pressure will push out the closure door. Different methods can be used to release the pressure from the launcher. Common methods are venting, draining, purging, and flaring the product. Note: Precautions need to be taken so that product is not released into the atmosphere. If the pipeline is running a liquid, Nitrogen may be used to purge the launching barrel. Refer to the Operator-specific guidelines for what method will be used. Ensure that no pressure exists in the barrel before opening barrel door. Now, that you have vented the pressure from the launcher, we must verify that all pressure has been removed. The process will be determined by the equipment being used. Several methods may be used to determine pressure build up. A couple of these methods could involve the use of : Gauges Closure pressure alert valve (which can also be referred to as a tattle tale) Note: Before conducting any type of pressure release, ensure that all ignition sources have been removed from the area. Verify device is loaded correctly. Now that the pressure has been released from the launcher, we can open the launcher closure. You may see many different types of launcher closures. Two commonly used types are: Screw end cap Breach type When loading the pig, it is important to stand off to the side of the launcher door. Do not stand in the line Page 8 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

9 of fire. The specific pigs may have different loading procedures such as the need for a crane or fork lift for the larger pigs. Refer to the manufacturer s instructions and the Operator s procedures for loading instructions. The key to look out for is to ensure that the rear of the pig is past the inlet of the launcher. In order to do this, some special equipment may be needed such as a push bar or hydraulic ram. Purge and/or pressurize the piping in preparation for launching. Now that the pig is loaded, the closure door can be closed. Next, you can purge and/or pressurize the piping in preparation for launching. Different sites may have different procedures for pressurizing the line. The key is to remove any unwanted gas from the launcher while adding the material that will be used to push the pig. One method for doing this is to seal the launcher door. Then add the media that will be used to push the pig while leaving the vent line open. This is known as line packing. Once the pressure can be seen at the vent valve, close the vent. Refer to your Operator instructions for the method to be used for your site. Place valves in correct position for launching the device and launch into piping system. Once the line has been pressurized, it will be necessary to place valves in the correct position for launching the pig into the piping system. This can be done by removing the isolation from the launcher and adding the media behind the pig. Once the pig has been launched, it is necessary to verify that it has left the launcher. There are several methods that can be used that include, but are not limited to: Pig Sig- or a pig signal system Visual observation- where you open the launcher to see if the pig has launched Note: When using the visual method, ensure that the proper steps for opening the closure door have been followed. Verify all identified valves are realigned for normal configuration. The Operator procedures will instruct you on how to place the valves once the operation is complete. Using the Operator-approved setting for all valves, you must verify all identified valves are realigned for normal configuration. Refer to your Operator diagram and operating procedure for steps to take. Skill Demonstrate how to perform a receiving operation Page 9 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

10 Now that you have an understanding of how to launch a pig, let s talk about how to perform a receiving operation. First, identify and locate the associated valves for the receiving operation. After you have identified and located the valves for the receiving operation, make sure the valves are functioning correctly. Follow the Operator s operating instructions for proper sequence and receiving pressures to be used. Next, verify that the pig is received correctly. You can view the pig sig markers to see if they have tripped. Ensure both pig sigs have tripped showing the pig is fully in the receiver. If a pig sig is not available, you can use a compass to find the front of the pig. Note: This method will only work for pigs that have magnets located in the front of the pig. Remove the product from the receiver and associated piping. Note: Before opening the receiver, ensure that all pressure has been removed from the barrel. Trapped pressure can push out past the pig with enough force to turn over a large front end loader. Once you ve ensured that no pressure exists in the barrel, you can open the door and start the unloading procedure. Verify unloading is completed correctly following all Operator instructions. Some key areas to consider are: The use of a tool puller to pull the pig from the receiver Additional PPE might be required on the receiver site Hazardous waste containment and NORM handling should be addressed Once the pig has been unloaded correctly, the receiver and piping should be purged to remove any potential hazardous conditions. Lastly, verify that all valves are realigned for normal configuration. Candidates 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. AOC Recognize: Unintentional release, vapors, or hazardous atmosphere could be signs that an abnormal operating condition has occurred. Examples could include, but are not limited to: Blowing Gas Page 10 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

11 Puddles Dead Vegetation Vapors from casing vents React/Respond: Proper responses to take in the event of unintentional release, vapors, or hazardous atmosphere included the following: Recognize: Eliminate potential ignition sources. Move to a safe location. Notify emergency response personnel, as appropriate. Limit access to the location, as necessary. Follow appropriate procedures for notification, documentation, and remedial action. Material defects, anomalies, or physical damage of pipe or a component that have impaired or are likely to impair the serviceability of the pipeline are abnormal operating conditions. Examples include, but are not limited to: Coupling defects Exposed pipeline Dents, and Gouges AOC React/Respond: Proper reactions/responses to take in the event of material defects, anomalies, or physical damage of pipe or a component that have impaired or are likely to impair the serviceability of the pipeline include the following: Determine the extent, cause and potential hazard(s) of the defect, anomaly, and/or damage. Mark the location so it may be easily located, as appropriate. Follow appropriate procedures for notification, documentation, and remedial action. AOC Recognize: Failure or malfunction of pipeline components is an abnormal operating condition. Examples could include, but are not limited to: Valve leaking Internal device stuck Pressure indicating device malfunction Launcher door safety devices fail React/Respond: Proper reactions/responses to take in the event of a failure or malfunction of pipeline component(s) include the following: Determine the extent, cause and potential hazard(s) of the defect, anomaly, and/or damage. Page 11 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017

12 Follow appropriate procedures for notification, documentation, and remedial action. Glossary Abnormal Operating Condition 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. Page 12 of 12 Copyright 2017 Veriforce, LLC. All rights reserved. 11/08/2017