Sutton Plant Design and Operations

1. Auflage 2014
ISBN: 978-0-323-31147-2
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 408 Seiten

Plant Design and Operations provides practical guidance on the design, operation, and maintenance of process facilities. The book is based on years of hands-on experience gathered during the design and operation of a wide range of facilities in many different types of industry including chemicals, refining, offshore oil and gas, and pipelines. The book helps managers, engineers, operators, and maintenance specialists with advice and guidance that can be used right away in working situations. Each chapter provides information and guidance that can be used immediately. For example, the chapter on Energy Control Procedures describes seven levels of positive isolation - ranging from a closed block valve all the way to double block and bleed with line break. The Safety in Design chapter describes topics such as area classification, fire protection, stairways and platforms, fixed ladders, emergency showers, lighting, and alarms. Other areas covered in detail by the book include security, equipment, and transportation. A logical, practical guide to maintenance task organization is provided, from conducting a Job Hazards Analysis to the issue of a work permit, and to the shutdown and isolation of equipment. Common hazards are covered in detail, including flow problems, high pressure, corrosion, power failure, and many more. - Provides information to managers, engineers, operators and maintenance personnel which is immediately applicable to their operations - Supported by useful, real-world examples and experience from a wide range of facilities and industries - Includes guidance on occupational health and safety, industrial hygiene and personal protective equipment

Ian Sutton is a chemical engineer with over thirty years of experience in the process industries. He has worked on the design and operation of chemical plants, offshore platforms, refineries, pipelines and mineral processing facilities. He has extensive experience in the development and implementation of process safety management and operational excellence programs. He has published multiple books including Process Risk and Reliability Management, 2nd Edition and Offshore Safety Management, 2nd Edition, both published by Elsevier.

Autoren/Hrsg.

Sutton, Ian

Inhaltsverzeichnis

1;Front Cover;1
2;Plant Design and Operations;4
3;Copyright Page;5
4;Contents;6
5;1 Operations;22
5.1;Introduction;23
5.2;Professional Advice;24
5.3;Regulations, Standards, and Guidance;25
5.3.1;Regulations;25
5.3.2;Industry Standards;25
5.3.2.1;ISO;26
5.3.2.2;ANSI;26
5.3.3;Guidance Documents;26
5.4;Units of Measurement;26
5.5;Risk Reduction;27
5.5.1;Risk Analysis;27
5.5.2;Quantification;27
5.6;Flammable and Combustible Materials;28
5.6.1;Flammable Range;28
5.6.2;Flammable Limits;28
5.6.3;Flash Point;28
5.6.4;Combustible Liquids;29
5.6.4.1;Class II liquids;30
5.6.4.2;Class III liquids;30
5.6.5;Flammable Liquids;30
5.6.6;Ignition Sources;31
5.7;Area Classification;32
5.8;Housekeeping;33
5.8.1;General Neatness;33
5.8.2;Proper Placement;34
5.8.3;Grass and Brush;34
5.8.4;Equipment and Piping;34
5.8.5;Storage and Handling of Flammable Liquids;34
5.8.5.1;Regulations and standards;35
5.8.5.2;Handling requirements;35
5.9;Nonprocess Operations;36
5.9.1;Outside Storage;36
5.9.2;Coal and Coke Storage;36
5.9.3;Drum Storage;37
5.9.4;Drainage;37
5.9.5;Fire Protection and Prevention;37
5.9.6;Cylinders;37
5.9.7;Loading Racks;38
5.10;Simultaneous Operations;39
5.10.1;Managing SIMOPs;40
5.10.2;SIMOPs Matrix;40
5.10.3;Conducting the SIMOPs;41
5.10.3.1;Kickoff meeting;41
5.10.3.2;Communication meetings;42
5.10.4;Closeout;43
5.11;Examples;43
5.11.1;Example 1—Facility Design;43
5.11.2;Example 2—Heat Exchanger;44
6;2 Maintenance and inspection;45
6.1;Introduction;46
6.2;Types of maintenance;46
6.2.1;Repair Maintenance;46
6.2.2;Condition-Based Maintenance;46
6.2.3;Scheduled Maintenance;47
6.2.4;Reliability-Centered Maintenance;47
6.3;Maintenance task organization;48
6.3.1;Step 1—Plan the Work;48
6.3.2;Step 2—Conduct a JHA;50
6.3.3;Step 3—Issue a Work Permit;50
6.3.4;Step 4—Shutdown and Isolate Equipment;51
6.3.5;Step 5—First Break;52
6.3.6;Step 6—Perform the Work;52
6.3.7;Step 7—Close Out the Work/Permit;52
6.3.8;Step 8—Handover to Operations;53
6.3.8.1;Readiness review;53
6.3.8.2;Mechanical completion;53
6.3.8.2.1;Physically complete and clean;53
6.3.8.2.2;Tight;53
6.3.8.2.3;Inspected, tested, and documented;53
6.4;Pressure tests;54
6.4.1;Maximum Allowable Working Pressure;54
6.4.2;Test Medium;55
6.4.3;Tightness Tests;56
6.4.4;Strength Tests;56
6.4.5;Testing Procedures;57
6.4.5.1;Hydrostatic (liquid);57
6.4.5.2;Pneumatic (gas);57
6.4.5.3;Installing blinds;58
6.4.6;Pressure Test Manual;59
6.5;Online cleaning and repair;59
6.6;Inspection;63
6.6.1;Regulations and Standards;63
6.6.2;Inspection Frequency;64
6.6.3;Inspection Records;65
6.6.4;Risk-Based Inspection;65
6.6.4.1;Analyze risk;65
6.6.5;Spare Parts;66
6.6.5.1;Determine costs;66
6.6.5.2;Allocate resources;66
7;3 Energy control procedures;67
7.1;Introduction;69
7.2;Regulations and standards;69
7.2.1;OSHA 29 CFR §1910.119;69
7.2.2;OSHA 29 CFR §1910.146;71
7.2.3;API 2015;71
7.2.4;API 2026;71
7.2.5;API 2217A;71
7.2.6;ANSI Z117.1;71
7.3;Removal of the hazard;71
7.4;Equipment and piping;73
7.4.1;Venting and Draining Requirements;75
7.4.2;Manways;76
7.4.3;Electrical Equipment;76
7.4.4;Mechanical Equipment;76
7.4.5;Pipe Plugs;76
7.5;Minimizing contact with air;77
7.5.1;Limiting Oxygen Concentration;77
7.5.2;Blanketing;77
7.5.3;Tank Filling and Emptying;80
7.5.4;Heavy Sludge Deposits;81
7.5.5;Spills and Overflows;81
7.5.6;Flame Propagation Through Drains;81
7.5.7;Catching Samples;82
7.5.8;Air-Blowing of Hydrocarbon Lines;83
7.6;Positive isolation;83
7.6.1;Level 1—Closed Valve;83
7.6.1.1;Control valves;85
7.6.1.2;Blowdown valves;85
7.6.1.3;Shutdown valves (offshore);85
7.6.2;Level 2—Closed Valve with Open Bleeder;86
7.6.3;Level 3—Double Block and Bleed;86
7.6.4;Level 4—Block and Bleed with Line Break;87
7.6.5;Level 5—Block, Bleed, and Spectacle Blind;87
7.6.6;Level 6—Double Block and Bleed with Blind;88
7.6.7;Level 7—Double Block and Bleed with Line Break;88
7.7;Lockout/tagout;89
7.7.1;Group Lockout;89
7.7.2;Lockboxes;90
7.7.3;Car Seals;91
7.7.4;Padlocks;91
7.7.5;Tags;91
7.7.6;Removing Locks and Tags;92
7.8;Electrical Isolation;93
7.9;Administrative Controls;93
7.10;Work permits;94
7.10.1;General Work Permits;94
7.10.1.1;Issuance of permits;95
7.10.1.2;Changes in conditions;95
7.10.1.3;Multiple work permits;96
7.10.2;Hot Work Permits;96
7.11;Confined-space entry;97
7.11.1;Types of Space;99
7.11.1.1;Nonhazardous space;99
7.11.1.2;Hazardous space;99
7.11.2;The Entry Permit;100
7.11.3;Personnel;101
7.11.3.1;Entrant;101
7.11.3.2;Supervisor;101
7.11.3.3;Manway attendant;102
7.11.3.4;Gas tester;102
7.11.3.5;Rescue team;102
7.11.4;Preparation;102
7.11.4.1;Job hazards analysis;103
7.11.4.2;Isolate the equipment;103
7.11.4.3;Drain liquids, purge, and ventilate;104
7.11.5;Test;105
7.12;Tie-Ins;105
7.13;Hot Tapping;106
7.14;Plugged lines;106
7.14.1;Prevention of Pluggage;106
7.14.2;Unplugging a Line;108
7.14.3;Mechanical;109
7.14.4;Differential Pressure;109
7.14.4.1;Fluid selection;110
7.14.4.2;Steam;111
7.14.4.3;Compressed gas;111
8;4 Occupational safety;112
8.1;Introduction;112
8.2;Measuring Performance;113
8.3;Safety manual;114
8.4;Behavior-based safety;119
8.4.1;Observed Hazard Card;120
8.4.2;Five-by-Five Policy;121
8.5;Lone Worker Policy;121
8.6;Incident Reporting;121
8.6.1;Reports;122
8.6.1.1;Vehicle incidents;122
8.6.1.2;Near misses;122
8.7;Portable Gas Detectors;122
8.8;Machinery safety;122
8.9;Fall protection;123
8.9.1;Definitions;123
8.9.2;Fall Protection System;124
8.9.3;Fall Arrest System Equipment;125
8.10;Dropped Objects;125
8.11;Compressed Gas Cylinders;126
8.12;Overhead power lines;126
8.13;Cranes and rigging;127
8.13.1;Lifting Precautions;127
8.13.2;Crane Operation;128
9;5 Chemicals;129
9.1;Introduction;129
9.2;Fluid Categories;130
9.3;Material safety data sheets;130
9.4;Global harmonization system;133
9.5;The safety diamond;134
9.6;Exposure limits;136
9.6.1;Emergency Response Planning Guidelines;136
9.6.2;Immediately Dangerous to Life and Health;138
9.6.3;Permissible Exposure Limits;138
9.6.4;Threshold Limit Values;138
9.6.5;Short-Term Exposure Limit;139
9.7;Benzene;139
9.8;Hydrogen fluoride;140
9.8.1;Unloading;140
9.8.2;KOH Beds;140
9.8.3;Dedicated Flare;140
9.9;Sulfur dioxide;141
9.10;Hydrogen sulfide;142
9.10.1;Toxicity;142
9.10.2;Flammability;143
9.10.3;Location of Monitors;143
9.10.4;Corrosion;144
9.11;Chlorine;145
9.12;Carbon Monoxide;145
9.13;Carbon Dioxide;145
9.14;Nitrogen;146
9.15;Lead;147
10;6 Personal protective equipment;148
10.1;Introduction;149
10.2;Employer Responsibility;149
10.3;Regulations and Standards;149
10.4;Clothing;150
10.4.1;Flame-Resistant Clothing;151
10.4.2;Impervious Clothing;152
10.4.3;Laboratory Clothing;152
10.4.4;Emergency PPE;152
10.4.4.1;Firefighter protective clothing;152
10.4.4.2;Proximity suits;153
10.5;Respiratory protection;153
10.5.1;Fixed Breathing Air Systems;153
10.5.2;Respirators;153
10.5.2.1;Air-purifying respirators;153
10.5.2.2;Supplied air respirators;154
10.5.2.3;Self-contained breathing apparatus (SCBA);154
10.5.2.4;Chemical canister rebreathers;154
10.5.2.5;Disposable respirators;154
10.5.2.6;Use of respirators;154
10.6;Head Protection;155
10.6.1;Additional Equipment/Markers;155
10.6.2;Color Schemes;156
10.6.3;Maintenance and Storage;156
10.7;Hand protection;156
10.8;Foot Protection;157
10.9;Eye protection;157
10.9.1;Safety Glasses;158
10.9.2;Chemical Goggles;158
11;7 Health and industrial hygiene;159
11.1;Introduction;160
11.2;Employee access to records;161
11.3;Asbestos;162
11.4;Noise;162
11.4.1;Regulations and Standards;163
11.4.1.1;MSHA 30 CFR 62;163
11.4.1.2;OSHA 1926.101—Hearing protection;163
11.4.1.3;OSHA 1910.95—Occupational noise exposure;163
11.4.1.4;NIOSH: Noise and hearing loss protection;163
11.4.1.5;EEMUA;164
11.4.2;Definitions;164
11.4.2.1;Decibel;164
11.4.2.2;Time-weighted average;164
11.4.2.3;Hertz;164
11.4.2.4;Noise dose;164
11.4.2.5;Threshold limit value;165
11.4.3;Noise Limits;165
11.4.3.1;Continuous noise;166
11.4.3.2;Intermittent or fluctuating noise;166
11.4.4;Noise Control;167
11.4.4.1;Remove the source;167
11.4.4.2;Modify the source;167
11.4.4.3;Relocation/barriers;168
11.4.4.4;Enclose equipment;168
11.4.4.5;Hearing protection;168
11.4.4.6;Administrative controls;168
11.4.5;Vibration Control;169
11.4.6;Industry Issues;169
11.5;Naturally occurring radioactive material;169
11.5.1;Regulations and Standards;170
11.5.2;TENORM;170
11.5.3;Exposure;170
11.5.4;Treatment;171
11.5.5;Water/Dry Blasting;171
11.5.6;Safe Limits;171
11.5.7;Protective measures;171
11.6;Lifting;171
11.7;Heat stress;172
11.7.1;Heat Index;172
11.7.2;Types of Heat Stress;172
11.7.3;Heat Stress Factors;173
11.7.4;Heat Stress Prevention;173
11.8;Cold stress;174
11.8.1;Types of Cold Stress;174
11.8.2;Equivalent Chill Temperature;175
11.8.3;Controlling Cold Stress;175
11.9;Radiant Heat;176
11.10;Food and galley hygiene;176
11.10.1;Methods of Preservation and Treatment;177
11.10.2;Treating Contamination;177
11.10.3;Storage and Cooking Temperatures;177
11.10.4;Facilities and Equipment;178
11.11;Alcohol and drug policy;178
11.11.1;Coverage;179
11.11.2;Affected Participants;179
11.11.3;Applicants for Employment;179
11.11.4;Testing;180
11.11.5;Contractors;180
12;8 Human factors and ergonomics;181
12.1;Introduction;182
12.2;Process Safety Management;182
12.3;Human Error;183
12.3.1;Errors of Intent;184
12.3.2;Errors of Action;185
12.3.2.1;Slips;185
12.3.2.2;Mistakes;185
12.3.2.3;Fixation;186
12.3.2.4;Error in an emergency;186
12.3.3;THERP;187
12.4;Ergonomics;188
12.4.1;Musculoskeletal Disorders;188
12.4.1.1;Fix the person;189
12.4.1.2;Fit the person to the task;189
12.4.1.3;Change the person;189
12.4.1.4;Change performance;189
12.4.1.5;Change the work or workplace;189
12.4.2;Work Stations;189
12.5;Human Factors on Projects;190
12.5.1;Phase I—Concept Selection;190
12.5.2;Phase II—Preliminary Engineering;190
12.5.3;Phase III—Detailed Engineering;191
12.6;Control Rooms;191
12.7;Valve Criticality Analysis;191
12.7.1;Category 1;192
12.7.2;Category 2;192
12.7.3;Category 3;192
12.8;Signs;193
12.8.1;Regulations and Standards;193
12.8.2;Types of Sign;194
12.8.2.1;Prohibition;194
12.8.2.2;Mandatory action;195
12.8.2.3;Warning;195
12.8.2.4;Safe condition;196
12.8.2.5;Fire safety;196
12.9;Labeling;197
12.10;Color Coding;197
12.10.1;Exposed Piping;198
12.10.2;Hoses;198
13;9 Firefighting;199
13.1;Introduction;200
13.2;Regulations and Standards;200
13.3;Principles of Firefighting;202
13.3.1;Remove the Fuel Source;202
13.3.2;Consequence and Likelihood;202
13.3.3;Safeguards;203
13.3.4;Single-Fire Concept;203
13.3.5;Fire Zones;203
13.4;Firewater;203
13.4.1;Water Capacity and Rates;205
13.4.2;Deluge Systems;205
13.4.3;Sources of Firewater;205
13.4.4;Testing;206
13.4.5;Firewater Pumps and Drivers;206
13.4.5.1;Jockey pumps;207
13.4.5.2;Main fire pumps;207
13.4.6;Fixed Water Spray Systems;207
13.4.7;Automatic Sprinkler Systems;208
13.4.8;Monitors/Hose Carts;208
13.4.9;Firewater Distribution System;208
13.4.9.1;Materials of construction;208
13.4.9.2;Layout;209
13.4.9.3;Deluge valves;209
13.4.9.4;Hydrants;209
13.4.10;Other Firefighting Media;209
13.4.10.1;Halon;209
13.4.10.2;Steam;210
13.4.10.3;Foam systems;210
13.4.10.4;Carbon dioxide;210
13.4.10.5;Earth-moving equipment;211
13.4.11;Underground Firewater Systems;211
13.5;Portable Fire Extinguishers;211
13.5.1;Location;211
13.5.2;Types;212
13.5.2.1;Water extinguishers;212
13.5.2.2;CO2 extinguishers;213
13.5.2.3;Dry chemical extinguishers;213
13.6;Training;213
14;10 Safety in design;215
14.1;Introduction;216
14.2;Units of Measurement;216
14.3;Fire Protection;216
14.3.1;Passive Fire Protection;217
14.3.2;Fireproofing;217
14.3.3;Fireproofing Materials;219
14.3.4;Fireproofing Insulation;220
14.4;Stairways, Ramps, and Platforms;220
14.4.1;Regulations and Standards;220
14.4.2;Terminology;221
14.4.2.1;Angle of ascent/inclination;221
14.4.2.2;Handrail;221
14.4.2.3;Riser;221
14.4.2.4;Tread;221
14.4.2.5;Overhead clearance;221
14.4.2.6;Stair width;222
14.4.3;Spiral/Winding Stairs;222
14.4.4;Landings;222
14.4.5;Design Load;223
14.4.6;Stair Rails;223
14.4.7;Stair Treads;223
14.4.8;Ramps;223
14.5;Fixed Ladders;224
14.5.1;Guidance;224
14.5.2;Safety Cages and Gates;226
14.5.3;Rungs and Stringers;227
14.5.4;Intermediate Platforms;228
14.5.5;Work Platforms and Walkways;228
14.5.5.1;Handrails and toeboards;229
14.5.5.2;Tank gauging platforms;229
14.5.5.3;Connected tanks;229
14.6;Emergency Showers and Eyewashes;229
14.6.1;Regulations and Standards;230
14.6.2;Risk Assessment;230
14.6.3;Release Points and Location;231
14.6.4;Safety Shower Design;233
14.6.4.1;Flow rates and pattern;234
14.6.4.2;Visibility and accessibility;234
14.6.4.3;Alarms;235
14.6.4.4;Electrical area;235
14.6.4.5;Freeze protection;235
14.6.4.6;Heat protection;236
14.6.4.7;Enclosures;236
14.6.5;Using the Shower;236
14.6.6;Inspection;236
14.6.7;Eyewash Units;237
15;11 Siting and layout;238
15.1;Introduction;240
15.2;Regulations and Standards;240
15.3;Siting;241
15.4;Layout;242
15.5;Spacing;244
15.5.1;Process Equipment;244
15.5.2;Property Lines;247
15.6;Blocks and Roads;247
15.6.1;Routine Access and Egress;247
15.6.2;Firefighting Access;248
15.6.3;Hazardous Chemical Areas;248
15.6.4;Secondary Containment;249
15.6.5;Drainage;249
15.7;Equipment;250
15.7.1;Vessels;250
15.7.2;Pumps;251
15.7.3;Hydrocarbon Storage Tanks;254
15.7.4;Compressors/Compressor Drivers;255
15.7.5;Heat Exchangers;255
15.7.6;Air Fin Coolers;255
15.7.7;Boilers and Steam Generators;256
15.7.8;Cooling Towers;256
15.7.9;Fired Equipment;257
15.7.10;Equipment Stacking;257
15.7.11;Air Intakes;258
15.8;Piping and Valves;258
15.9;Utilities;259
15.9.1;Instruments and Cables;260
15.9.2;Electrical Substations;260
15.9.3;Bare-Wire Electric Power Lines;261
15.10;Buildings;261
15.10.1;Occupied Buildings;263
15.10.2;Electrical Rooms/Substations;263
15.10.3;Pressurized Enclosures;263
15.10.4;Process Buildings;264
15.10.5;Temporary Buildings;264
15.10.6;Control Buildings;265
15.10.7;Control Laboratories/Analyzer Buildings;266
15.10.8;Warehouses;266
15.10.9;Inside Storage;267
15.10.10;Operator Shelters;267
15.10.11;Electrical Equipment Buildings;267
15.10.12;Nonprocess Buildings;268
15.11;Loading and Unloading;268
15.12;Emergency Equipment;269
15.12.1;Process Isolation Valves;269
15.12.2;Emergency Stations;269
15.12.3;Hydrants and Monitors;269
15.13;Fire and Gas Detection;269
15.13.1;Regulations and Standards;270
15.13.2;Layout of Detectors;270
15.13.3;Responses;271
15.13.4;Fire Detection;272
15.13.4.1;Flammable gas detection;273
15.13.4.2;Fire/flame detection;273
15.13.4.3;Heat detection;274
15.13.4.4;Fusible links;274
15.13.4.5;Smoke detection;274
15.13.4.6;Ultrasonic detectors;274
15.13.4.7;Closed-circuit television;275
15.13.5;Toxic Gas Detection;275
15.14;Manual Alarm Call Points;276
15.15;Offshore Facilities;277
15.15.1;Safe Areas;277
15.15.2;Operations;278
15.15.3;Emergency Evacuation and Rescue;278
15.15.4;Temporary Refuge;278
15.15.5;Wellbay Area;280
15.15.6;Drilling Rigs;281
15.15.7;Pipeline Equipment;282
15.15.8;Fire Protection/Fire and Gas Detection;282
15.15.9;Helidecks;283
15.15.10;Transfer Areas;283
15.15.11;Piping;283
15.15.12;Rotating Equipment;284
16;12 Equipment;285
16.1;Introduction;286
16.2;Pressure Vessels;286
16.2.1;Regulations and Standards;286
16.2.2;Factory Acceptance Tests;288
16.2.3;Vessels Under Vacuum;289
16.2.4;Reflux Vessels;289
16.2.5;Small Pipe Connections;289
16.3;Storage Tanks;290
16.3.1;Fixed Roof Tanks;290
16.3.2;Floating Roof Tanks;292
16.4;Pumps;293
16.4.1;Pump Casing;294
16.4.2;Seals and Packing;294
16.4.3;Minimum Flow Bypass;295
16.4.4;Pump Isolation;296
16.4.5;Safety Issues;296
16.5;Compressors;297
16.5.1;Liquid Knockout on the Compressor Suction;297
16.5.2;Relief Valves;297
16.5.3;Compressor Isolation;297
16.5.4;Shutdown and Alarm Systems;297
16.6;Heat Exchangers;298
16.6.1;Shell and Tube Heat Exchangers;298
16.6.2;Air-Cooled Exchangers;299
16.6.3;Cooling Towers;299
16.7;Fired Heaters;301
16.7.1;Start-up of Fired Heaters;301
16.7.2;Air Preheaters;303
16.7.3;Fired Heater Burnout;303
16.8;Boilers;304
16.9;Internal Combustion Engines;304
16.9.1;Starter Systems;305
16.9.2;Intake, Exhaust, and Fuel Systems;306
16.10;Electrical equipment;306
17;13 Piping and valves;308
17.1;Introduction;309
17.2;Piping;309
17.2.1;Materials;309
17.2.2;Insulation;310
17.2.3;Gaskets;310
17.2.4;Threaded Piping;310
17.2.5;Thermal Expansion;310
17.2.6;Identification and Labeling of Pipes;311
17.2.7;Testing and Inspection;311
17.3;Blinds;311
17.3.1;Line Blinds;312
17.3.2;Spectacle Blinds;312
17.4;Valves;312
17.4.1;Block Valves;312
17.4.2;Valve Seat Material;313
17.4.3;Self-Closing Valves;313
17.4.4;Check Valves;313
17.4.5;Emergency Isolation Valves;313
17.4.6;Excess Flow Valves;314
17.4.7;Trapped Liquids;314
17.4.8;Plugs;314
17.5;Pressure relief devices;315
17.5.1;Design Parameters;315
17.5.2;Regulations and Standards;315
17.5.3;Pressure Safety Relief Valves;315
17.5.4;Pilot-Operated Pressure Relief Valves;318
17.5.5;Thermal Relief Valves;319
17.5.6;Discharge Piping;320
17.5.7;Testing and Inspection;321
17.5.8;Rupture Disks;322
17.5.9;Hatches/Doors;323
17.6;Flame arrestors;323
17.6.1;Thermal Flame Arrestors;324
17.6.2;Detonation Arrestors;325
17.6.3;Water Seal-Type Flame Arrestors;325
17.6.4;Velocity-Type Flame Arrestors;325
17.7;Flares;326
17.7.1;Engineering Standards;326
17.7.2;Types of Flare;326
17.7.3;Smokeless Operation;327
17.7.4;Location of Flares;327
18;14 Safety instrumentation;328
18.1;Introduction;328
18.2;Alarms;329
18.2.1;Alarm Design;329
18.2.2;Alarm Management;329
18.3;Safety instrumented systems;330
18.3.1;Regulations and Standards;331
18.3.2;IEC 61511;331
18.3.3;IEC 61508;332
18.3.4;Safety integrity level;332
18.3.4.1;Design;333
18.3.4.2;Quantitative analysis;333
18.3.4.3;Testing and inspection;334
18.3.5;Emergency Shutdown;334
18.4;HIPPS;335
19;15 Transportation;337
19.1;Introduction;337
19.2;Regulations and Standards;338
19.2.1;Static Electricity;338
19.2.2;Offshore;338
19.2.3;Trucks;338
19.3;Road Vehicles;338
19.3.1;Vacuum Trucks;338
19.3.2;All-Terrain Vehicles;340
19.4;Loading/Unloading;340
19.4.1;General Procedures;341
19.4.2;Control Measures;342
19.4.3;Bonding;343
19.4.4;Switch Loading;343
19.4.5;Tank/Railcars;343
19.4.6;Additives;344
19.5;Marine Transport;344
19.5.1;Personnel Transfer Baskets;345
19.5.2;Cargo Baskets;348
19.5.2.1;Rigid frame baskets;349
19.6;Helicopters;349
19.6.1;Guidance;349
19.6.1.1;Personnel movement;350
19.6.1.2;Air turbulence;350
19.6.1.3;Rescue;350
19.6.2;Regulations and Standards;350
20;16 Security;353
20.1;Introduction;353
20.2;Regulations and Standards;355
20.3;Types of Attack;355
20.3.1;Members of the Public;355
20.3.1.1;Vandalism;356
20.3.1.2;Theft;356
20.3.1.3;Activists;356
20.3.2;Sabotage;356
20.3.3;Terrorism;357
20.3.3.1;Visible security;357
20.3.3.2;Population density;357
20.3.3.3;High profile;358
20.4;Security Vulnerability Analyses;358
20.4.1;Rings of Protection;358
20.4.2;Cybersecurity;359
20.5;Managing Security;359
20.5.1;Culture;359
20.5.2;Inherent Safety;360
20.5.3;Access Security;360
20.5.4;Personnel Screening;360
20.5.5;Equipment Modifications;360
20.6;Response to a threatening call;360
21;17 Common hazards;364
21.1;Introduction;366
21.2;Process Hazards;366
21.2.1;High Flow;366
21.2.2;Low/No Flow;367
21.2.3;Reverse Flow;367
21.2.4;Misdirected Flow;368
21.2.5;High Pressure;368
21.2.6;High Temperature;368
21.2.6.1;Blocked-in pump;369
21.2.6.2;Polymerization;370
21.2.6.3;External fire;370
21.2.7;Low Pressure;370
21.2.8;Low Temperature;371
21.2.9;High Level;371
21.2.10;Wrong Composition;371
21.2.11;Corrosion;372
21.2.12;Chemical Embrittlement;373
21.2.13;Strong Oxidizers;374
21.2.14;Static Electricity;374
21.3;Hazards of Utilities;374
21.3.1;Common Cause Failure;374
21.3.2;Process Contamination;374
21.3.3;Electrical Power Failure;375
21.3.4;Nitrogen;375
21.3.5;Reverse Flow to a Utility Header;375
21.3.6;Survivability of Utilities;376
21.4;Hazards of Water;376
21.4.1;Water in Hydrocarbon Tanks;377
21.4.2;Water in Very Hot Liquid;377
21.4.3;Water and Firefighting;378
21.5;Hazards of Steam;378
21.5.1;Steaming Vessels During Turnaround;378
21.5.2;Reboiler Leak;379
21.5.3;Wet Steam In Turbines;380
21.6;Hazards of Ice;380
21.6.1;Line Freezing;380
21.6.2;Hydrates;380
21.7;Hazards of Compressed Gas;380
21.7.1;Gas Cylinders;381
21.7.2;Pigging Incident;381
21.8;Hazards of Air;381
21.8.1;Flammable Mixture;381
21.8.2;Blowing a Line Clear;382
21.9;Hazards of external events;382
21.9.1;Flooding;382
21.9.2;Lightning;383
21.9.2.1;Earthquakes;383
21.10;Hazards of Equipment and Instruments;383
21.10.1;Furnace Firing;383
21.10.2;Fired Heater Burnout;383
21.10.3;Multiple Uses of Equipment;384
21.10.4;Distributed Control Systems;385
21.11;Hazards of Piping, Valves, and Hoses;386
21.11.1;Piping;386
21.11.1.1;Pipe class transition;386
21.11.1.2;Hydraulic hammer;387
21.11.1.3;Pig launchers and receivers;387
21.11.1.4;Pressure in relief headers;387
21.11.1.5;Overload of overhead vacuum lines;388
21.11.1.6;Underground piping;388
21.11.1.7;Vents and bleeders;388
21.11.2;Hoses;388
21.11.2.1;Hoses and truck pull-away;389
21.11.2.2;Hose run over;389
21.11.2.3;Hose failure;389
21.11.2.4;Backflow preventor;389
21.11.2.5;Temporary connection;389
21.11.3;Valves;390
21.11.3.1;Block valves below relief valves;390
21.11.3.2;Fail-safe control valves;391
21.11.4;Shared Relief Valve;392
21.11.5;SDV Bypass;393
22;References;396
23;Index;398

Leseproben

Chapter 2

Maintenance and inspection

The previous chapter discussed some of the normal operating issues to do with process facilities. This chapter describes the related topic of maintenance, where the term maintenance refers to repairing equipment that has failed or taking corrective action before the item actually does fail. Larger changes to the system are handled through the Management of Change (MOC) program—discussed in detail in . Even larger changes constitute stand-alone projects in their own right.

Keywords

Maintenance; Reliability-centered maintenance; Condition-based maintenance; Scheduled maintenance; Job Hazards Analysis; JHA; Pressure test; MAWP; Maximum allowable working pressure; Tightness test; Strength test; Cleaning; Repair; Inspection; Risk-based inspection

Chapter Outline

Introduction 25

Types of Maintenance 25

Repair Maintenance 25

Condition-Based Maintenance 25

Scheduled Maintenance 26

Reliability-Centered Maintenance 26

Maintenance Task Organization 27

Step 1—Plan the Work 27

Step 2—Conduct a JHA 29

Step 3—Issue a Work Permit 29

Step 4—Shutdown and Isolate Equipment 30

Step 5—First Break 31

Step 6—Perform the Work 31

Step 7—Close Out the Work/Permit 31

Step 8—Handover to Operations 32

Readiness review 32

Mechanical completion 32

Pressure Tests 33

Maximum Allowable Working Pressure 33

Test Medium 34

Tightness Tests 35

Strength Tests 35

Testing Procedures 36

Hydrostatic (liquid) 36

Pneumatic (gas) 36

Installing blinds 37

Pressure Test Manual 38

Online Cleaning and Repair 38

Inspection 42

Regulations and Standards 42

Inspection Frequency 43

Inspection Records 44

Risk-Based Inspection 44

Analyze risk 44

Spare Parts 45

Determine costs 45

Allocate resources 45

Introduction

The previous chapter discussed some of the operating issues to do with process facilities. This chapter describes the related topic of maintenance, where the term maintenance refers to repairing equipment that has failed or taking corrective action before the item actually does fail. Larger changes to the system are handled through the Management of Change (MOC) program—discussed in detail in Even larger changes constitute stand-alone projects in their own right.

Also discussed in this chapter are inspection and the terms “Mechanical Completion” and “pressure test.”

Types of maintenance

Maintenance work falls into one of the following four categories:

1. Repair

2. Condition-based maintenance

3. Scheduled maintenance

4. Reliability-centered maintenance (RCM)

All but the first of these can be placed in the overall category of preventive or preventative (either spelling is acceptable) maintenance.

Repair Maintenance

The most common type of maintenance is the repair of an item which has failed or which is showing imminent signs of failure. This type of maintenance tends also to be the most hazardous because there may not be much time to plan the job, and the repair work may be going on while the rest of the facility is in operation. In addition, the maintenance workers may be under pressure to get the work done quickly in order to avoid a larger system shutdown. Such pressure may lead to shortcuts being taken.

Condition-Based Maintenance

Condition-based maintenance is carried out when an equipment item starts to show early signs of failure or when its performance becomes degraded. For example, if the discharge pressure of a pump starts to fall the pump may be taken out of service and repaired before it actually fails.

Condition-based maintenance tends to be less hazardous than repair maintenance because it can be properly planned, and it can be carried out without the workers feeling that they are in a rush. Ideally, condition-based maintenance will be carried out while the unit is shut down, thus making conditions even safer for the maintenance workers.

Examples of monitoring activities that could lead to the need for condition-based maintenance include the following:

• Process performance

• Vibration analysis

• Oil analysis

• Thermography.

Scheduled Maintenance

Some equipment and instrument items are serviced on a scheduled basis, regardless of the actual performance or condition of those items. A common example of this type of maintenance is the routine replacement of lubricating and seal oils.

Table 2.1 provides an example of the maintenance schedule of an instrumentation system.

Table 2.1

Example of an Instrument Loop Maintenance Schedule

Item

Months

High integrity protection loops

6

Shutdown and alarms systems (SIL2)

6

Shutdown and alarms systems (SIL1)

12

Control and monitoring systems

24

Nonsafety alarms

24

Indicators

24

Ancillary instruments

36

Reliability-Centered Maintenance

Reliability-centered maintenance (RCM) uses a risk-based approach to organizing maintenance activities. As such, it is analogous to risk-based inspection (RBI), a topic that is discussed later in this chapter. This approach is based on the elements of risk as shown in Equation (1.1). Those items that contribute the most to overall risk receive a higher maintenance priority than those that are considered to be less critical. (In practice, the RCM program may focus more on the consequence term than on overall risk.)

An RCM analysis is typically built around the following steps:

1. A component list is developed for the section of the facility that is being analyzed.

2. A failure analysis, possibly using the Failure Modes & Effects Analysis (FMEA) method, is carried out for each component.

3. A criticality is assigned to each failure mode.

4. A scheduled maintenance program that focuses on the high criticality items is set up. This program can be condition-based.

The RCM program should include a process for analyzing equipment failures and applying the lessons learned from those analyses such that overall risk can be reduced. The analysis can also help determine the required inventory for spare parts.

Maintenance task organization

The organization of a maintenance task can be divided into the following eight steps:

1. Plan the work

2. Conduct a risk assessment or job hazards analysis (JHA)

3. Issue a work permit and prepare tools and personnel

4. Shutdown and isolate the affected equipment

5. Make the first break

6. Perform the work

7. Close out the work and the permit

8. Handover to operations

Figure 2.1 shows an overview of the above steps.

Figure 2.1 Maintenance planning.

Step 1—Plan the Work

The first step is to determine what the task is and how it is to be done. This step also means identifying and listing the affected pieces of equipment and determining what impact the maintenance work is likely to have on the overall operation. For a large, continuously operating unit, an important part of the plan is to determine what other parts of the facility will have to be shut down and to determine how those items that are to be left running are to operate during this particular maintenance task. Therefore, an isolation plan is required.

It is very important at this stage to determine if the work is truly routine maintenance, or if it falls under the scope of the MOC program.

Before maintenance work starts it is important to check that the following activities have been carried out:

• All equipment is either on site or scheduled for delivery (components should be assembled in an area adjacent to where the work is taking place).

• Piping is fabricated in advance.

• Everything is field verified and...