Guidelines for Preparing Process Equipment for Maintenance and Return to Service E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 277

Veröffentlichungsjahr: 2025

Beschreibung

This book contains comprehensive information and methodologies for preparing process equipment for maintenance and, ultimately, return to service. Specifically, this book addresses two phases of equipment handovers, providing information and tools to help personnel at manufacturing sites reduce their risks. The first phase is isolating and preparing equipment for maintenance. The second phase is returning the equipment back to service, applying specified operational readiness plans in addition to a traditional pre-startup safety review (PSSR).

Topics include understanding the unique types of hazards personnel might be exposed to, planning for and executing decontamination and de-energization plans, and safely recommissioning the equipment for its return to service. Case studies, examples, and incident investigation discussions provide the reader with invaluable practical learnings that, when applied, help reduce the likelihood of another similar operational incident from occurring at their facility.

Leseprobe

Table of Contents

Cover

Table of Contents

Title Page

Copyright

LIST OF FIGURES

LIST OF TABLES

LIST OF CASE STUDIES

ACRONYMS AND ABBREVIATIONS

GLOSSARY

ACKNOWLEDGMENTS

DEDICATION

FOREWORD

PREFACE

1 INTRODUCTION

1.1. PURPOSE AND SCOPE OF THE BOOK

1.2. KEY DEFINITIONS RELEVANT TO PREPARING EQUIPMENT FOR MAINTENANCE AND RETURN TO SERVICE

1.3. OVERVIEW OF THE MAIN FOCUS AREAS

2 REGULATION AND PROCESS SAFETY

2.1 REGULATORY ASPECTS

2.2 COMPANY STANDARDS AND SAFE SYSTEMS OF WORK

2.3 PROCESS SAFETY AND PERSONAL SAFETY

3 UNDERSTANDING THE HAZARDS

3.1 INFORMATION REQUIREMENTS‐PROCESS SAFETY INFORMATION

3.2 EQUIPMENT HAZARDS

3.3 ENERGY HAZARDS

3.4 SIMULTANEOUS OPERATIONS

3.5 HUMAN FACTORS

3.6 FREQUENTLY ENCOUNTERED ISSUES WHEN PREPARING EQUIPMENT FOR ISOLATION

3.7 SUMMARY

Note

4 Planning for Isolation and Decontamination

4.1 Plan Considerations

4.2 Risk Assessment

4.3 Isolation/Decontamination – Which Comes First?

4.4 Planning The Energy Isolation

4.5 Planning for Decontamination and Decommissioning

4.6 Disposal of Chemicals from Decontaminated Processes

4.7 Planning for Return to Service

4.8 Changing Plans

5 The Decontamination Plan

5.1 Documented Plan

5.2 Phase of Decontamination

5.3 Managing the Decontamination Hazards and Risks

5.4 Training for Decontamination

5.5 Difficult Decontaminations

5.6 Moving Decontaminated Equipment

5.7 Checklists and Equipment Identification

6 EXECUTING THE DECONTAMINATION PLAN

6.1 Sharing the Plan

6.2 Tracking the Plan

6.3 Completing and Documenting Execution of the Plan

6.4 Complex Decontamination Plans

6.5 Equipment Readiness for Energy Isolation

6.6 Summary

7 Isolation and Decontamination Plan Examples

7.1 Isolating/Decontaminating Lines with Toxic Materials using “Double Block and Bleed”

7.2 Isolation/ Decontamination for Vessel Entry

7.3 Isolation for Longer Term/Mothballing

7.4 Isolating/Decontaminating Butyl Lithium Storage Systems

7.5 Example – Isolating/Decontaminating a Toluene Diisocyanate Reactor Train

7.6 Summary

Notes

8 Overview of Energy Isolation

8.1 Degrees of Isolation

8.2 Human Factors in Energy Isolation

8.3 Designing for Energy Isolation

8.4 Locking and Labelling

8.5 Documenting Energy Isolation

8.6 Chemical Process Isolation

8.7 Electrical Isolation

8.8 Mechanical, Potential and Natural Energy Sources

8.9 Nuclear Radiation

8.10 Summary

9 Written Energy Isolation Plans (EIP)

9.1 De‐isolation, Testing, and Restart Considerations

9.2 Risk Level

9.3 Documentation ‐ Safe Work Permit and EIP

9.4 Piping and Instrument Diagram (P&ID) Symbols for Process Isolation

9.5 Forms and Types of Energy Isolation

9.6 Lock – Tag ‐ Try

9.7 Final Verification Before Release to Work

9.8 First Line Break

9.9 Monitoring Isolations

9.10 Summary

10 SPECIFIC ISOLATION REQUIREMENTS

10.1 PROCESS/INSTRUMENT ISOLATION

10.2 ELECTRICAL ISOLATION

10.3 MECHANICAL AND POTENTIAL ENERGY AND NATURAL ENERGY ISOLATION

10.4 NUCLEAR RADIATION

10.5 BOUNDARY ISOLATION

10.6 SPECIALIZED ISOLATION TECHNIQUES

10.7 FIELD VERIFICATION AND CHANGES TO ISOLATION

10.8 SUMMARY

Note

11 REVERSING THE ISOLATION PLAN

11.1 JOB COMPLETION AND TRANSFER OF EQUIPMENT OWNERSHIP

11.2 DE‐ISOLATION PROCEDURE

11.3 PROCESS DE‐ISOLATION

11.4 VENTS AND DRAINS

11.5 DE‐ISOLATION OF OTHER SOURCES OF ENERGY

11.6 CLEANLINESS

11.7 BOLTS, FLANGES, AND GASKETS

11.8 CHANGES TO ISOLATION BOUNDARY

11.9 SUMMARY

12 RECOMMISSIONING

12.1 CHECKS FOR DEBRIS

12.2 CLEANING AND FLUSHING

12.3 PURGING

12.4 LEAK/PRESSURE TESTING

12.5 FUNCTIONAL CHECKS

12.6 WALK THE LINE (WTL)

12.7 DELAYED RETURN TO SERVICE

Note

13 PRE‐STARTUP SAFETY REVIEW

13.1 PSSR AND RETURNING EQUIPMENT TO SERVICE

13.2 PSSR OVERVIEW

13.3 PSSR EXAMPLE: SHORT FORM

13.4 SUMMARY

14 EQUIPMENT STARTUP

14.1 PARTICIPATION AND COMMUNICATION

14.2 SPECIFIC STARTUP ISSUES

14.3 STARTUP OF MOTHBALLED EQUIPMENT

15 CONCLUSION

APPENDIX A: WORK PERMITWORK PERMIT

Note

APPENDIX B: WALK THE LINEWALK THE LINE

WALK THE LINE

CONDUCT OF OPERATIONS & THE WALK THE LINE MODEL

MANAGEMENT DISCIPLINE

OPERATIONAL DISCIPLINE

ENGINEERING DISCIPLINE

WALK THE LINE TOOLS

WALK THE LINE APPLICATION TO PREPARING EQUIPMENT FOR AND RETURNING FROM MAINTENANCE

SUMMARY

APPENDIX C: DECONTAMINATION CERTIFICATE

APPENDIX D: Long Form for higher risk/complex pssr

REFERENCES

Index

End User License Agreement

List of Tables

Chapter 3

Table 3-1 Equipment Hazard Examples

Table 3-2 Energy Hazards

Table 3-3 Chemical Hazard Examples

Table 3-4 Frequently Encountered Issues to be Considered

Chapter 4

Table 4-1 Example Job Safety Analysis Worksheet

Table 4-2 Planning for Return to Service

Chapter 5

Table 5-1 Key Components of Decontamination Plan

Chapter 6

Table 6-1 Decontamination Checklist

Chapter 7

Table 7-1 Isolation and Decontamination Steps for Hazardous Material

Table 7-2 Decontamination for Vessel Entry

Table 7-3 Isolation and Decontamination Checklist

Table 7-4 Return to Service Checklist

Table 7-5 Outline Standard Operating Procedure for Isolation and Decontamin...

Chapter 8

Table 8-1 Relative Security Level of Isolation Types for Different Energy S...

Table 8-2 Typical Energy Isolation Documentation and Respective Usage

Chapter 13

Table 13-1 Global Examples of Pre‐Startup Safety Review Related Documents

Table 13-2 Example Short Form for Lower Risk/Simple PSSR

Appendix C

Table C-1. Decontamination Certificate

Appendix D

Table D-1 Example Long Form for Higher Risk/Complex PSSR

List of Illustrations

Chapter 1

Figure 1-1 Flowchart for Equipment Maintenance and Return to Service

Chapter 4

Figure 4-1 First Line Break Against Single Valve

Figure 4-2 Purge Valve Fitted to Blind Flange

Chapter 6

Figure 6-1 Fire at Husky Refinery (CSB, 2022)

Chapter 7

Figure 7-1 Isolation Design for a Piping System Containing a Toxic Liquid Ch...

Figure 7-2 Vessel Isolation Schematic for Confined Space Entry

Figure 7-3 Diagram of TDI CSTR System (1 of 2) Figure 7-3 Diagram of TDI CS...

Chapter 8

Figure 8-1 Spectacle Blind Shown in Open Position

Figure 8-2 Fast Acting Blind Valves

Figure 8-3 Electrical Isolator Lock

Figure 8-4 Multi‐hasp and Lock Box

Chapter 9

Figure 9-1 Key to Typical P&ID Symbols for Energy Isolation

Figure 9-2 Process Isolation with Increasing Integrity of Isolation

Chapter 10

Figure 10-1 Electrical Switchbox Used for Training

Chapter 11

Figure 11-1 Remains of Piper Alpha on the Morning Following the Explosions a...

Figure 11-2 De‐isolation with Unproven Absence of Energy Source

Figure 11-3 De‐isolation with Ability to Prove Absence of Energy Source

Figure 11-4 De‐isolation with Bleed Valve Allowing to Check for Absence of E...

Chapter 13

Figure 13-1 High Level PSSR Workflow Chart

Appendix A

Figure A-1 Safe Work Permit – Page 1 of 2

Appendix B

Figure B-1 Conduct of Operations Management System Model

Guide

Cover Page

Table of Contents

Series Page

Title Page

Copyright

LIST OF FIGURES

LIST OF TABLES

LIST OF CASE STUDIES

ACRONYMS AND ABBREVIATIONS

ACKNOWLEDGMENTS

DEDICATION

FOREWORD

PREFACE

Begin Reading

APPENDIX A WORK PERMIT

APPENDIX B WALK THE LINE

REFERENCES

Index

End User License Agreement

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PUBLICATIONS AVAILABLE FROM THE CENTER FOR CHEMICAL PROCESS SAFETY OF THE AMERICAN INSTITUTE OF CHEMICAL ENGINEERS

This book is one in a series of process safety guidelines and concept books published by the Center for Chemical Process Safety (CCPS). Refer to www.wiley.com/go/ccps for full list of titles in this series.

It is sincerely hoped that the information presented in this document will lead to a better safety record for the entire industry; however, neither the American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers' officers and directors, nor BakerRisk, and its employees and subcontractors warrant or represent, expressly or by implication, the correctness or accuracy of the content of the information presented in this document. As between (1) American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers' officers and directors, and BakerRisk and its employees and subcontractors, and (2) the user of this document, the user accepts any legal liability or responsibility whatsoever for the consequence of its use or misuse.

Guidelines For Preparing Process Equipment For Maintenance And Return To Service

CENTER FOR CHEMICAL PROCESS SAFETY of the AMERICAN INSTITUTE OF CHEMICAL ENGINEERS120 Wall Street, 23rd Floor · New York, NY 10005

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Library of Congress Cataloging‐in‐Publication Data Applied for:

Hardback ISBN: 9781394237890

Cover Images: Silhouette, oil refinery © manyx31/iStock.com, Stainless steel © Creativ Studio Heinemann/Getty Images, Dow Chemical Operations, Stade, Germany/Courtesy of The Dow Chemical Company

LIST OF FIGURES

Figure 1‐1 Flowchart for Equipment Maintenance and Return to Service

Figure 4‐1 First Line Break Against Single Valve

Figure 4‐2 Purge Valve Fitted to Blind Flange

Figure 6‐1 Fire at Husky Refinery

Figure 7‐1 Isolation Design for a Piping System Containing a Toxic Liquid Chemical

Figure 7‐2 Vessel Isolation Schematic for Confined Space Entry

Figure 7‐3 Diagram of TDI CSTR System

Figure 8‐1 Spectacle Blind Shown in Open Position

Figure 8‐2 Fast Acting Blind Valves

Figure 8‐3 Electrical Isolator Lock

Figure 8‐4 Multi‐hasp and Lock Box

Figure 9‐1 Key to Typical P&ID Symbols for Energy Isolation

Figure 9‐2 Process Isolation with Increasing Integrity of Isolation

Figure 10‐1 Electrical Switchbox Used for Training

Figure 11‐1 Remains of Piper Alpha on the Morning Following the Explosions and Fires

Figure 11‐2 De‐isolation with Unproven Absence of Energy Source

Figure 11‐3 De‐isolation with Ability to Prove Absence of Energy Source

Figure 11‐4 De‐isolation with Bleed Valve Allowing to Check for Absence of Energy Source

Figure 13‐1 High Level PSSR Workflow Chart

Figure A‐1 Safe Work Permit

Figure B‐1 Conduct of Operations Management System Model

LIST OF TABLES

Table 3‐1 Equipment Hazard Examples

Table 3‐2 Energy Hazards

Table 3‐3 Chemical Hazard Examples

Table 3‐4 Frequently Encountered Issues to be Considered

Table 4‐1 Example Job Safety Analysis Worksheet

Table 4‐2 Planning for Return to Service

Table 5‐1 Key Components of Decontamination Plan

Table 6‐1 Decontamination Checklist

Table 7‐1 Isolation and Decontamination Steps for Hazardous Material

Table 7‐2 Decontamination for Vessel Entry

Table 7‐3 Isolation and Decontamination Checklist

Table 7‐4 Return to Service Checklist

Table 7‐5 Outline Standard Operating Procedure for Isolation and Decontamination

Table 8‐1 Relative Security Level of Isolation Types for Different Energy Sources

Table 8‐2 Typical Energy Isolation Documentation and Respective Usage

Table 13‐1 Global Examples of Pre‐Startup Safety Review Related Documents

Table 13‐2. Example Short Form for Lower Risk/Simple PSSR

Table C‐1 Decontamination Certificate

Table D‐1 Example Long Form for Higher Risk/Complex PSSR

LIST OF CASE STUDIES

Case Study 2‐1 — Replacing a Sensor: New Design Leads to a Fire!

Case Study 2‐2 — No Isolation: Possible Radiation Danger!

Case Study 4‐1 — Breaking into the Wrong Line

Case Study 4‐2 — Chemical Exposure

Case Study 4‐3 — Isolation on an Oil Refinery

Case Study 4‐4 — Isolated but Not Fully Decommissioned ‐ 1

Case Study 4‐5 — Left a Valve Dead‐leg – Not Fully Decommissioned ‐ 2

Case Study 4‐6 — Isolated Longer than Intended

Case Study 5‐1 — Toxic Break‐in

Case Study 5‐2 — Refinery Storage Tank Explosion

Case Study 5‐3 — Solids Plugged in a Thermosyphon Reboiler

Case Study 5‐4 — The Tank That Was Not Isolated

Case Study 5‐5 — Pyrophoric Ignition of Structured Packing in a Crude Vacuum Column

Case Study 6‐1 — Explosion/Fires at Refinery During Maintenance Turnaround

Case Study 6‐2 — Decontamination of a Toxic Pipeline

Case Study 8‐1 — Electrical Low Voltage Isolation

Case Study 9‐1 — Lack of Energy Isolation

Case Study 9‐2 — Inadequate Isolation

Case Study 9‐3 — Filter Cartridges Change Out

Case Study 9‐4 — Flash Fire Caused by Inadequate Isolation

Case Study 9‐5 — Safety Relief Valve LOTO Compromised

Case Study 10‐1 — Vapor Cloud Explosion at Phillips 66 Facility

Case Study 11‐1 — Piper Alpha

Case Study 12‐1 — Vent Line Blockage

Case Study 12‐2 — Vessel Failure During Pneumatic Pressure Test

Case Study 12‐3 — Thermal Oil System Boil Over and Fire

Case Study 12‐4 — Process Safety Scrubber: Testing is Key!

Case Study 12‐5 — Spare Reboiler Explosion

Case Study 13‐1 — Oil Pipe Rupture after Commissioning

Case Study 13‐2 — Fire Heater Explosion after Restart

Case Study 14‐1 — Kleen Energy Natural Gas Explosion

Case Study 14‐2 — ARCO Channelview Compressor Explosion

Case Study 15‐1 — Solvent Release from Bleed on a ‘Double Block and Bleed’ Valve

ACRONYMS AND ABBREVIATIONS

ACOP

Approved Codes of Practice

ACC

American Chemistry Council

AIChE

American Institute of Chemical Engineers

BLEVE

Boiling Liquid Expanding Vapor Explosion

CCPS

Center for Chemical Process Safety

CFR

Code of Federal Regulations

CISCC

Chloride Induced Stress Corrosion Cracking

COD

Consequence of Deviation

COMAH

Control of Major Accident Hazards

CSB

Chemical Safety Board (US)

CSTR

Continuously Stirred Tank Reactor

DB&B

Double Block and Bleed

DCS

Distributed Control System

DSEAR

Dangerous Substances and Explosive Atmospheres Regulations

EA

Environment Agency

EIP

Energy Isolation Plan

EPA

Environmental Protection Agency

FCC

Fluid Catalytic Cracking

FMEA

Failure Mode and Effects Analysis

FMECA

Failure Modes, Effect and Criticality Analysis

GMP

Good Management Practice

HASAWA

Health and Safety at Work Act

HAZOP

Hazard and Operability Study

HDPE

High Density Polyethylene

HIRA

Hazard Identification and Risk Analysis

HRSG

Heat Recovery Steam Generator

HSE

Health and Safety Executive

HSG

Health and Safety Guidance

ICI

Imperial Chemical Industries

ILO

International Labor Office

IOGP

International Association of Oil and Gas Producers

ISO

International Organization for Standardization

ITPM

Inspection, Testing, and Preventive Maintenance

JSA

Job Safety Analysis

KO

Knock Out [drum]

LEL

Lower Explosive Limit

LNG

Liquefied Natural Gas

LOPA

Layer of Protection Analysis

LOPC

Loss of Primary Containment

LOTO

Lock‐Out Tag‐Out

LPG

Liquefied Petroleum Gas

MAWP

Maximum Allowable Working Pressure

MIC

Microbiological Introduced Corrosion

MOC

Management of Change

NDE

Non‐destructive Examination

NFPA

National Fire Protection Association

NORM

Naturally Occurring Radioactive Material

NRC

Nuclear Regulatory Commission

OECD

Organization for Economic Cooperation and Development

OEM

Original Equipment Manufacturer

ONR

Office for Nuclear Radiation

OSHA

Occupational Safety and Health Administration

P&IDs

Piping & Instrumentation Diagrams

PEI

Positive Equipment Identification

PFD

Process Flow Diagram

PHA

Process Hazard Analysis

PIS

Pyrophoric Iron Sulfide

POSM

Propylene Oxide/Styrene Monomer

PPE

Personal Protective Equipment

PRD

Pressure Relief Devices

PSE

Process Safety Event

PSI

Process Safety Information

PSM

Process Safety Management

PSSR

Pre‐Startup Safety Review

PSV

Pressure Safety Valve

PTW

Permit to Work

RBPS

Risk Based Process Safety

RMP

Risk Management Program

SCBA

Self‐contained Breathing Apparatus

SCTA

Safety Critical Task Analysis

SDS

Safety Data Sheets

SEPA

Scottish Environment Protection Agency

SIMOPS

Simultaneous Operations

SME

Subject Matter Expert

SOL

Safe Operating Limit

SOP

Standard Operation Procedure

SSOW

Safe Systems of Work

SWA

Stop Work Authority

TIH

Toxic Inhalation Hazard

TLV

Threshold Limit Values

UNEP

United Nations Environment Programme

UV

Ultraviolet

VRU

Vapor Recovery Unit

WTL

Walk the Line