start up unit

7/27/2019 Start Up Unit

1/40

Start Up Unit

Pre-startup checks

At the completion of this topic you must be able to perform pre-startup checks.

Pre-startup checks must be carried out to minimise problems during startup that could:

waste raw materials and energy produce excessive amounts of product that is off-specification cause equipment damage and lost production time cause injury to personnel.

Pre-startup checks ensure all equipment is in a safe and operational condition for startup.

Pre-startup checks carried out on a unit system must ensure:

all work permits are signed off the area around the unit equipment is clear of obstructions, debris or spills all blinds are removed from equipment lines as specified on the blind list all pipe work is connected and flanges tightened all hatches and access doors are shut and sealed instruments are connected equipment has been purged of air (if necessary) and pressure tested as required safety valves and pressure relief valves are checked and pressure tested as

required lines, vessels and columns have been purged to remove air, chemical or

hydrocarbon vapours block valves are in the correct startup positions services are available and lined up to the battery limits which may include:

cooling water steam and condensate return plant and instrument air process water nitrogen.

feeds are available to the reactor product streams are lined up to downstream units or storage valve status is correct for startup:

all line-ups to and from the reactor are correct

drain valves are closed to prevent spills vessel vents and PSV bypasses are closed.

electrical supply is connected to the plant instruments and instrument lines are fitted and functional heating/cooling systems are ready for operation duty and standby pumps are operational, primed and correctly set for automatic

operation vessels that were drained during maintenance are refilled plants supplying the reactor unit, or downstream of the unit, are notified of the

startup.


2/40

Pre-startup checks prevent damage to equipment and injury to personnel

Before starting a unit in your workplace refer to the StandardOperating Procedures

Activity OPS300A-11-1

Choose the best answer.Unit pre-startup checks are needed to prevent:

equipment damage.

injury to personnel.

excessive offspec product.

all of these.


Which three of the following pre-startup checks would most likelyrequire communication with other plant units?


3/40

Supply of services.

Hatches shut.Feed supply lined up to unit.

Duty pumps ready for operation.

Valves lined up within the unit.

Sufficient product storage.

Start Up Unit

Unit startup

At the completion of this topic, you must be able to:

start up individual items of equipment and the entire unit build up rate steadily stabilise operation to produce at the specified rate with appropriate product quality

within the minimum of time.

The procedures outlined for equipment startup are generic and may not apply to all types ofequipment.

Refer to your Standard Operating Procedures for the correctway to operate each type of unit in your workplace

Refer to Standard Operating Procedures for each item of equipment in the unit

Typical steps in starting a unit may include:

ensuring supplies of raw materials and feeds are adequate purging vessels with nitrogen or another inert gas to remove:

oxygen which can cause undesirable oxidation reactions or an explosion


4/40

residues such as product, sludge, water, air or vapours which cancontaminate the process material.

starting powered equipment starting the heating or cooling system adding the correct quantity of feeds and additives setting pressure and temperature controllers to the specified values controlling flows, pressure and temperature during and after the start up cycle sampling the process material trimming the unit by adjusting temperature, pressure and feed composition to

obtain on-specification product.


Before you start up any item of equipment in the field it is usuallynecessary to tell the:

relief operator.

laboratory superintendent.

emergency response team.

duty operator in the control room.


The best way to minimise the amount of offspec material normallygenerated during startup is to:

ignore gauge readings until they are correct.

minimise the startup time.

disable the interlocks.

ignore all alarms.



5/40

Two reasons for purging a vessel before startup are to remove:

oxygen which may react with chemicals in an undesirable way.

heat which may slow down the reaction.

materials that may contaminate the product stream.

heat that may cause the reactants to explode.


Which of the following is NOT a strategy for ensuring a steadybuild-up of rate to achieve onspec product in the most efficientway?

Add the correct quantity of feed materials and additives.

Start heating/cooling systems before the process stream.

Monitor flows, pressure and temperature during and after the

startup cycle.

Sample the purged material.

Start Up Unit

Start up after maintenance

At the completion of this topic you must be able to start up normally and after maintenance.


6/40

Sign off all permits

When starting equipment after maintenance, checks are required to ensure themaintenance work has been safely completed and the equipment is ready for startup.

When starting after maintenance, checks made may include:

all work permits are signed off spades and blinds have been removed from equipment lines all lines are connected and flanges tightened all vents and drains are closed lines and vessels are purged to remove air block valves are in the correct operating position

instrument lines are connected control valves are in the correct operating position safety valves and pressure relief valves are correctly set and installed pumps are operational and primed safety system bypasses are removed vessels that were drained during maintenance are refilled all tools are removed from the unit area.


Indicate if the following statements are: True False

It is all right to start up equipment before work permitsare signed off as long as you tell one other operator.

You should check that spades and blinds have beenremoved after maintenance and before startup ofequipment.

Vessels that were drained during maintenance must not


7/40

be refilled until after startup.

After maintenance, equipment should be brought onlinegradually to reduce the chance of damage.

Send to Tutor Activity OPS300A-13-2

1. Select an appropriate unit at your workplace. It must not be a reactortrain, distillation unit, furnace system or compressor unit. However, itshould be similar in complexity to any of these.

2. Describe the type of equipment and include a labelled sketchshowing all inlets/outlets and major parts. Indicate where utilities areused. Show waste streams.

3. Create a checklist for safe startup after maintenance

Start Up Unit

Assessment tasks

To be recognised as competent in this

section you must be assessed in boththe knowledge content and theworkplace skills. The knowledgecontent is assessed online and theworkplace skills are demonstrated toyour workplace assessor.

Sub topicsOnline assessment

Workplace assessment

You may undertake the assessment if you are ready, or review the material inthis section again.

If you would like more information on the assessment process refer to theStudent Guide.

To be assessed as competent in the topic you must demonstrate the ability todo the following.

Start Up Unit

1.1 Perform pre-startup checks

1.2 Start up individual items of equipment and the entire unit

1.3 Start up normally and after maintenance
http://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC300/PROC300-010401-OnlineAssessment.htmhttp://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC300/PROC300-010401-OnlineAssessment.htmhttp://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC300/PROC300-010402-WorkplaceAssessment.htmhttp://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC300/PROC300-010402-WorkplaceAssessment.htmhttp://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC300/PROC300-010402-WorkplaceAssessment.htmhttp://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC300/PROC300-010401-OnlineAssessment.htm


8/40

1.4 Build up rate steadily

1.5 Stabilise operation to produce at the specified rate withappropriate product quality within minimum time

Monitor and Control the Unit

Routine checks and paperwork

At the completion of this topic you must be able to complete routine checks, logs andpaperwork.

The various types of units used in the chemical, hydrocarbons and oil refining industries havedifferences that effect their operation.

The procedures outlined are generic and may not apply to all types of unit equipment.

Refer to your Standard Operating Procedures for the correctway to operate each type of equipment in your workplace

There are two main ways to record routine checks:

using a paper based system using a computer based system.

An Operational Technician may have to complete forms, sheets, logs and reports such as:

plant equipment checklists for routine housekeeping and serviceability checks aswell as startup and shutdown sequences

shift/unit logs to record work activities and observations history sheets of instrument readings to determine trends instrument field logs of readings for comparison with the set limits of operation test reports that indicate product quality incident reports for investigating unusual events, spills and accidents maintenance request systems for equipment repairs and parts replacement shift hand over logs to indicate all significant activities to be communicated.

All checklists, logs and paperwork must be completed and forwarded to the relevantpersonnel by the required times in accordance with the Standard Operating Procedures.

All important process variables must be regularly monitored and the readings entered intologs, so that trends and histories can be maintained.



9/40

Select six correct answers.Process problems can be investigated by looking at theinformation recorded in:

plant equipment checklists.

shift/unit logs.

history sheets.

instrument field logs.

test reports.

incident reports.

maintenance request systems.

shift hand over logs.

For organisations that are using computers the paper-based logs, forms, sheets and reportshave been replaced by fields on a screen that you enter field data into.

Typical parameters monitored may include:

process temperatures process pressures feed rates feed temperatures feed compositions product withdrawal rates product compositions.

A deviation from a normal reading for a process variable may indicate a problem which mustbe rectified as quickly as possible to prevent:

equipment damage and downtime offspec product.

Production rates and times are recorded into production logs so that if a problem occurshistorical data can be retrieved.

Equipment checks should be entered into checklists and any defective equipment enteredinto the maintenance request forms.


10/40

All paperwork must be filled out to ensure safe and efficient equipment operation

Regular field inspections must be carried out and any faulty equipment, safety orhousekeeping problems must be entered in the appropriate log.

Maintain logs at all times

Regular sampling of feed and products is required to determine:

the quality of feed composition that products are to specification.

Product samples are tested at regular intervals to ensure the product continually remains on-specification.


Select two correct answers.Samples of materials are regularly withdrawn and tested tomonitor:

process temperature.

process pressure.

feed rate.

feed temperature.


11/40

feed composition.

product withdrawal rate.

product composition.


Equipment problems are entered into the Shift Log so that:

someone else can fix the problem.

problems are communicated at handover.

maintenance will fix the problem straight away.

the supervisor knows where you have been.


Unit problemsAt the completion of this topic, you must be able to:

recognise the signs of potential and actual problems take action to minimise the impact on safety, health, the

environment and the business of actual and potentialproblems.

Typical problems that may occur in a unit system are:

process temperature too high

off-specification product loss of heating or cooling vessel or pipe rupture large drop in pressure across the equipment reduced flows.


12/40

Signs of unit equipment problems must be recognised at an early

stage when actioncan be taken to prevent damage to equipment or injury to personnel

Reactor temperature too highA too high temperature in the unit can be caused by:

loss of cooling incorrect feed composition.

Action taken to reduce a too high unit temperature can include:

shutting down the unit reducing feed flow

shutting off heat supply to the unit increasing flow of coolant to the unit reducing temperature of coolant.


Which of the following actions could be taken toreduce a process temperature which is toohigh?

Turn off the coolant flow.

Increase the feed to slow the reaction.

Reduce the flow of steam to the unit.

All of the above.


13/40

Off-specification product

Product can become off-specification for many different reasons, butsome factors which can contribute to off-specification product are:

sample taken was not a true representative sample, or thesampling method was incorrect

faulty instruments feed variations impurities in feed incorrect mixing/blending times or quantities incorrect process temperature leaking water jackets or coolant tubing contaminating the

process material incorrect maintenance procedures.

Loss of heating or coolingLoss of heating or cooling in the unit could be caused by:

fouling of metal surfaces in heat exchanger tubes, waterjackets or coils - reducing heat transfer

faulty steam traps causing condensation to build up insteam heating coils

heating or cooling medium not lined up to exchanger,water jackets or coils

sticking temperature control valve or faulty control circuit partial or total loss of utilities.

The unit must be monitored regularly to pick up problems

Large pressure dropA large drop in pressure can occur across unit equipment due to aflow restriction caused by:

scale build-up and fouling of pipes foreign materials blocking pipes and vessel outlets


14/40

blocking of filters and screens downstream blockage or flow restriction incorrect valve lineup to downstream equipment causing a

bottleneck.


Indicate if the followingstatements are: True False

Offspec product due to

contamination, may be caused byruptured coolant tubing

Process heating efficiency is reducedwhen exchanger tubes are fouled.

Flow restrictions caused by ablockage in a vessel will greatlyincrease the pressure drop acrossthe vessel.

Corrective actionOnce problems are identified in a unit, corrective action can beapplied as shown in the following table.

Unit problem Action taken to correct off-specification product

Improper sample If operating parameters appearnormal, take new samples and havethem analysed.

Faultyinstruments

Test the critical instruments used tomeasure temperatures, pressuresand flows, then repair or replaceany faulty instruments.

Feed variationsor impurities infeed

Take a new feed sample foranalysis and compare the resultsagainst the initial feed sample.

Any change in feedcomposition or properties


15/40

will require unit operatingparameters to be trimmed toprevent offspec product.

Any impurities in the feed

that adversely affects theproduct quality must beremoved, or feed must betaken from an alternativesource.

Faultymaintenance

Wrong materials used duringmaintenance, or incorrect assembly,can adversely affect the operationof the unit.A maintenance shutdown will have

to be scheduled to make repairs asrequired.

Incorrect mixingtimes or feedmixtures

Procedures must be followed toensure:

correct quantities andproportions of feed materialsand additives are used

correct mixing times areadhered to.

Leaking waterjackets orexchangers

Equipment suspected of leakingmust be pressure tested to findleaks. Leaky water jackets orexchangers must be repaired toprevent contamination of reactantsand product.

Poor qualitycatalyst

Catalyst must be changed over orregenerated to remove poisons.

Fouling of metalsurfaces in heatexchangers/waterjackets or tubes

Check temperature rise or fallacross the heat exchanger, waterjackets or tubes. If temperature riseor fall is less than normal, foulinghas occurred which will require:

washing internal surfaces ofexchangers, water jackets orcoils with cleaning solutionthen flushing with water orsteam to remove cleaning

solution


16/40

mechanical cleaning withabrasives, brushes, etc.

Heating or coolingmedium not linedup to exchangers,water jackets ortubes

Ensure valve line-up to and fromexchangers is correct and valves arefully open.

Stickingtemperaturecontrol valve orfaulty controlcircuit

Lubricate, service and testcontrol valve

Test control circuit Remove process material

build-up from probe.

Large drop inpressure acrossequipment

Remove surface scaling orfouling

Remove blockage Check valve line ups.


Monitor the unit

At the completion of this topic, you must be able to:

frequently and critically monitor all plant throughout shift use measured/indicated data and smell, sight, sound

and feel as appropriate to monitor plant identify critical equipment/processes and tune their

performance identify issues likely to impact on plant performance and

take appropriate action.

Process variables that may need to be monitored in a unit caninclude:

temperature pressure flow rates mixing time motor rpm chemical composition.


17/40

Plant must be frequently and critically monitored

TemperatureThe temperature in a unit generally controls the rate of chemicalreactions as well as the physical condition of materials.

An increase in the temperature of a process will generally increase

such things as:

rate of evaporation/boiling melting of waxes amount of dissolved material viscosity rate of reaction.

Changes in feed temperature must be recognised quickly so thatadjustments can be made before there is a loss of control in theunit.

Excessive temperatures in the unit can lead to the production ofoffspec product, dangerously high pressures, equipment damage,shutdowns, and costly equipment downtime for repairs.

In a unit process where temperatures are likely to rise abovedesirable levels, the temperature must be monitored. Thetemperature can be reduced by:

reducing the flow rate of feeds into the unit increasing the flow rate of coolant through the cooling

system decreasing the inlet temperature of the coolant.

Temperature chart showing normaloperation.

This temperaturechart is showingnormal operation.The temperatureis monitored atthe inlet and atthe outlet of theunit.


18/40

Temperature out of control betweentime t2and t3

An alert operatorshould be able tonotice the upwardtemperature trendbetween t1 and t2.

Early warning of a problem allows the operator to take correctiveaction, such as the application of more cooling or a reduction in

feed, to avoid out-of-control conditions that may cause offspecproduct or lead to a hazardous situation.

One probe shows a high

temperature while the other isnormal

Possible causesof the above chartare a faultyinstrument, ablockage or partialfailure of thecooling system,which may lead toa temperature

gradient betweenthe inlet and theoutlet of the unit.Each of thesepossibilities couldbe checked.

PressureThe pressure in a unit vessel can influence product quality and therate of throughput, so careful monitoring is needed. Excessivelyhigh pressure can damage piping or seals.

Abnormally low pressure in the unit normally means that there is aleak, loss of the feed, or a broken compressor.

High pressure generally means that there is a blockage in the unitor outlet, or the temperature may be excessive. All other thingsbeing equal, if the temperature increases, the pressure willincrease too. Screens and filter beds should be checked for signsof blockage.

Extreme pressures have the potential to rupture vessels or causeseals to fail with considerable leakage. Bursting disks and pressuresafety valves (PSVs) are designed to relieve the pressure safelybefore the vessel is damaged. These safety devices are normally


19/40

installed in lines that lead to a flare or scrubber to preventdischarges going directly to the atmosphere.

When the pressure is excessively high you could reduce the feedof materials by putting compressors or pumps on bypass.

MixingGood mixing of materials is essential to obtain quality products withuniform properties.

Uneven mixing of process materials will produce products withuneven properties making off-specification product.

Chemical compositionImpurities contained in feeds can gum up equipment, or alter thechemical and physical properties of the process material.

The impurities can:

reduce production rates of desirable materials increase production of offspec material or waste.

Process material must be sampled at regular intervals to ensure itschemical composition remains the same - so that a consistent andonspec quality material is produced.


Select two correct answers.Excessively high pressure in a unit vessel canbe reduced by:

throttling back the outlet valve.

decreasing the temperature.

decreasing the feed.

taking feed compressors or pumps off by-pass.


20/40

Using your sensesOperators can use the senses of feel, smell, sight and sound toidentify process and equipment problems. Typical problems thatcan be identified by using your senses are listed below.

Your eyes will identify unusual process events such as:leaks, spills and product that is the wrong colour.

Your ears will pick up unusual sounds in the equipmentsuch as: noises caused by failed bearing problems,cavitation, mixing problems, high pressure leaks,missing gear teeth and damaged agitators.

Abnormal temperatures can sometimes be detected byplacing your hand near a piece of equipment. Abnormaltemperatures can be caused by motors (and associatedequipment) overheating because of an increased load or

a loss of lubrication.

When about to touch equipment todetermine hot and cold spots, do not gonear:

rotating gears excessively hot or cold surfaces acidic, alkaline or toxic

chemicals.

Your nose will pick up unusual smells caused byoverheated exchangers, electrical cables burning andoffspec product.

Use your senses to identify problems


21/40


Which senses are most likely to enable you todetect a gas leak during a field inspection?

Sight and smell.

Hearing and touch.

Hearing and smell.

Sight and touch.


Select two correct answers.Overheating equipment can be detected duringa field inspection by:

smell.

sight.

hearing.

touch.


22/40

Equipment isolation

At the completion of this topic you must be able to prepare for maintenance/vessel entry asrequired.

Before any maintenance work is carried out on the unit, all relevant work permits must beobtained and the equipment must be isolated from:

the electrical supply to prevent electrocution mechanical movement to prevent physical injury flowlines in or out of the equipment to prevent spills, fire, explosions or injury to

personnel during confined space entry.

Equipment must be isolated before maintenance or vessel entry as requiredby work permits or confined space entry permits

Electrical isolationAny equipment that has an electrical connection must be electrically isolated by a suitablyqualified electrician before maintenance by:

opening the circuit breaker or removing a fuse at the electrical substation attaching a lock and a Do Not Operate tag to the circuit breaker or fuse.

Mechanical isolationIf the movement of any mechanical device can cause injury during maintenance, it must bestopped, usually by stopping the electric motor drive, followed by:

electrically isolating the power supply to the electric motor drive removing drive belts or drive chains removing shafts or couplings attaching locks and Do Not Operate tags where required.

Refer to Standard Operating Procedures when isolatingequipment

Isolation of FlowlinesFeed lines, product lines or heating/cooling lines that pass into and out of the equipment must beisolated by:

removing pipe sections, spool pieces, or valves inserting full pressure spades between flanges


23/40

inserting full pressure blanks onto the end of open flanges.

Isolation list

Isolations carried out on a piece of equipment should be listed and signed for on an appropriateisolation list.

Isolation for confined space entryA confined space is any enclosed or partially enclosed space which:

is at atmospheric pressure during occupancy is not intended or designed primarily as a place of work may have restricted means for entry and exit may have an atmosphere which contains potentially harmful levels of contamination may not have a safe oxygen level may cause engulfment.

Confined spaces include:

storage tanks, tank cars, process vessels, boilers, pressure vessels, silos and other

tank-like compartments open-topped spaces such as pits or degreasers pipes, sewers, shafts, ducts and similar structures.

Entering a confined space is a hazardous operation, which requires isolating the vessel toprevent:

explosions due to opening pressurised vessels suffocation due to working in a confined space atmosphere which is toxic or oxygen

deficient injuries due to liquids or gas leaking into the confined space through flowlines fire or explosions due to leakage of combustible gas or liquid injuries due to remnants of chemicals or gas left inside the vessel injury due to electrical/mechanical equipment startup.


24/40

It is important to have a suitably equipped standby person present.

A standby person must be present when entering a confined space

Confined space entry requires:

electrical isolation and tagging of electrical driven equipment such as pumps orcompressors

depressurisation and draining of feed, product and utility lines purging, gas freeing and flushing of the vessel the removal of pipe sections or spool pieces to isolate flowlines that pass into and out

of the vessel the use of spades or blanks to isolate flowlines that pass into and out of the vessel cleaning to remove dangerous chemicals from inside the vessel.

Purge vessel to remove gas


25/40

Use spades or blanks to isolate flowlines

Double block and bleed valve isolation is not normally adequatefor confined space entry requirements. Standard OperatingProcedures and the Permit To Work system must be strictlyadhered to when isolating equipment for a confined space entry

A confined space Entry Work Permitmust be obtained and signed off before the workcommences. This will detail the conditions under which the work may proceed. Many peoplehave died as a result of entering confined spaces. The permit system is designed to protectagainst hazards.


Isolation of flowlines is required before vessel entry to ensure that:

mechanical equipment is not started.

the vessel does not become electrically live.equipment is not energised.

process material does not enter the confined space.



26/40

For this activity you may need to speak to an experienced operator or yoursupervisor.

Obtain a copy of a work permit that has been prepared to allow work inside a vessel.

State the work to be carried out. Foreach safety precaution listed or checked on thepermit, briefly explain the nature of the hazard and how the precautionary measurelimits the potential for injury.

For example, for vessel entry: wear breathing apparatus to prevent inhalation of toxicfumes and to guard against asphyxiation in an oxygen deficient atmosphere.

Send this information to your tutor.

Send or Fax the information to your tutor.Note: always include a cover sheet with required information, such as name of tutor,

student, unit and activity number.


Which of the following methods is the best way to ensure that allfeed product lines for a unit have been isolated for vessel entry?

Shut off all the valves and hang a Do Not Operate tag on each

one.Tick off every item on the isolation list as you spade/blank eachline.

Shut two valves on each line leading to and from the vessel.

Shut one valve on each line and open a bleeder valve on thevessel side next to each valve.


Confined space entry, particularly for a vessel, requires special precautions to betaken. In each of the following, briefly describe the nature of the hazard and how theprecaution can help to prevent injury.

1. Electrical isolation and tagging of mechanical mixing equipment.2. Flush and steam clean the vessel.3. Isolate (spade or blank) all lines.


27/40

4. Purge and ventilate the vessel.

Maintain Plant Effectiveness

Minor maintenance

At the completion of this topic you must be able to complete minor maintenance in accordancewith Standard Operating Procedures.

Many minor maintenance tasks are required for safe and efficient plant operation. Theseactivities may be based on Standard Operating Procedures and could include:

installing couplings tightening or replacing gaskets installing blanks or spades tightening leaking glands on pumps and valve stems changing over and cleaning strainers and filters draining sludges.

If any flowlines, pumps, or filters are to be opened, the equipment must first be:

inspected for possible hazards using the Permit To Work system with appropriatepermits being used

isolated to prevent fluids entering the lines depressurised to prevent blowouts purged and flushed to remove hazardous substances.

If entry is required to a vessel, the vessel must be fully isolated, depressurised, drained,decontaminated, gas freed and gas tested before entry using:

Standard Operating Procedures Permit To Work System Confined Space Entry Procedures.


28/40

Sign off all permits

Cleaning, inspection, or minor maintenance to the inside of unit equipment must be carried out inaccordance with the Standard Operating Procedures.

Personal Protective Equipment must be used as specified in theStandard Operating Procedures even for a minor maintenancetask


Maintenance may be carried out on a pump seal:

after getting a permit but before isolation.

after isolation but before getting a permit.

after getting a permit and isolating the equipment.

Activity PROC300-44-2

Select two correct answers.Before you loosen flanges to install or remove blinds you must

check that:


29/40

new gaskets have been fitted.

the lines are depressurised.

Do Not Operate tags are in place.

the maintenance work has been carried out.

Send to tutor Activity OPS300A-44-3

A particular unit vessel has a hatchway near the top where bags of powder aretipped in. Some of the powder has spilled down the outside of the vessel and on tothe floor below.

You have been asked to clean up the spilled material. Briefly describe theprecautions you should take before and during the performance of this task using awater jet.

Send this information to your tutor.

Send or Fax the information to your tutor.Note: always include a cover sheet with required information, such as name of tutor,student, unit and activity number.


When you break a flange, why do you start to undo the bolts on theopposite side to where you are standing?

It is easier to undo the last few bolts since they will be on thesame side as you.

If the line is pressurised it is less likely to spray onto you.

If is easier to get good leverage on bolts that are on the oppositeside to where you are standing.

All of the above.


30/40


When you open a line to replace a valve you should always:

use new gaskets to ensure a good seal.

replace the gaskets because the old ones won't fit any more.

use the same gaskets to save money.

use the same gaskets because you already know they fit.

Preparing for operation

At the completion of this topic you must be able to:

receive plant back from maintenance prepare plant for the introduction of chemicals and operation.

Receiving a reactor back from maintenanceAfter the completion of minor maintenance to the unit, the unit must be received back from

maintenance and prepared for operation.

This may involve tasks such as:

ensuring all the conditions on the Permit to Work system have been fulfilled checking that all tools and equipment are removed from vessels checking that all hatches to vessels are closed and sealed purging the unit with an inert gas to remove contaminants removing blinds or blanks from lines in and out of the unit equipment as shown in the

blind list replacing sections of pipe, spool pieces, valves and connecting lines as shown on the

isolation list pressurising the unit with steam or inert gas to test for leaks depressurising the unit after leak testing is complete

repair any leaks before startup. filling the unit with inert gas checking that all auxiliary equipment is operational draining liquids such as water from equipment and lines checking that:

all work permits are signed off and returned the area is in a safe condition electrical isolations are removed by qualified electrical personnel valves are correctly lined up and in the pre-startup position.

Before startup, checks are required to ensure all equipment, including equipment not worked on


31/40

during maintenance, is in a safe and operational condition.

Check all lines are connected

Pre-startup checks will ensure that:

all flanges, valves and instruments are connected

all blinds and spades are removed all lines are connected valves are lined up and set to the pre-startup position all equipment is in a safe operational condition levels are correct in vessels all utilities are available and lined up all vents and drains are closed all instruments are connected and operating correctly

Resolve Problems

Identify problems

At the completion of this topic, you must be able to identify possible problems in equipment orprocess.

Identify problems needing action

In a typical workplace, the plant is monitoredby sensors and instrumentation that measureand display temperature, pressure, flow ratesand so on. To alert operators to a potential orexisting problem, alarms are set to respond ifa parameter being monitored goes outside acertain range.

Also some problems will cause the equipment or a complete process to trip off line. For example,if the water level in a boiler goes below or above preset values, the whole system will trip off lineto prevent water entering steam lines.

However, it is not typically possible to use sensors and instrumentation to allow every aspect ofan item of equipment or a process to be monitored from a central control room. For example it'simpractical to display the temperature of every bearing in the plant, or the state of every gland or


32/40

valve.

Even if this was the case, there are many other aspects that can only be monitored by looking atthe actual equipment rather than relying on instrumentation, alarms and trips.

For this reason it's important to become familiar with all equipment and processes in your workarea so that you can identify:

normal operation and

abnormal operation.

As part of the monitoring process, you should make regular field inspections using smell, sight,sound and feel to monitor any problems.

Smell can be used to detect:

overheated equipment leaks burning rubber or oil vapour.

Sight can be used to detect:

sticking valves or actuators faulty gauges damage to pumps, couplings or valves leaking seals on pumps or valves spills.

Sound can be used to detect:

liquid hammer in valves and other fluidflow equipment

cavitation in pumps faulty bearings faulty operation of equipment steam leaks.

Feel can be used to detect:

excessive vibration abnormal motor or bearing

temperatures overheated equipment.

You should also become familiar with local instrumentation readings, such as temperaturegauges fitted to bearings, or pressure gauges measuring particular pressures such as inlet waterpressure. Results of routine inspections and monitoring must be compared against normaloperating parameters to identify any operational problems.


33/40

Smell, sight, sound and feel are tools for identifying equipment problems. Experience and athorough knowledge of the process and equipment is often required to detect operationalproblems that are not monitored by instruments.

Warning: Senses such as sight, sound, smell and feel are usefulin detecting operational problems but cannot be relied on wheresafety and health issues are involved.

Discussion Activity OPS300A-71-1

In some cases, a certain level of skill is needed to identify a workplace problemneeding action.

Your task for this activity is to work with other operators to participate in a discussionabout how potential problems can be recognised and assessed by operators withinthe Chemical/oil refining industry.

Arrange with your tutor to organise a group discussion with other learners. This

could be either face-to-face or by using a web-based forum or live chat if available.

Provide an example of how a workplace problem needing action was recognisedearly at your workplace. Present your observations to the group and ask them toreview it and provide you with some feedback.

Use the information from the discussion to complete the following activity and sendanswers to your tutor.


34/40

Determine problems needing action

At the completion of this topic, you must be able to determineproblems needing action.

Determining if a problem needs remedial actionThere are many types of problems likely to be found in a complexplant or facility. Typical types of problems involve:

the process feed, product and intermediate materials equipment communication and operating procedures.

As a operations technician you need to be able to clearly state theproblem, the effect on the process or plant and how the problem has

been indicated.

If you detect a potential problem in equipment or a process youshould either:

report the problem, or rectify the problem if it's within your area of responsibility

and skill level.

However, it's important to determine if indeed there is a problembefore doing something about it. For example you might hear anunfamiliar sound that you suspect means a bearing is starting to fail.

However, a closer check might reveal that the sound you arehearing is in fact normal for that equipment.

If a reading is outside specifications,it's important to note the reading anddo something about it, such asmaking further checks on otherrelated instrument readings todetermine the extent of the problem.

To start the solution process, for each problem list the possiblecauses. In a complex process there may actually be many causes.

There are many types of problems likely to be found in a complexplant or facility. Typical types of problems involve:

the process equipment communication and operating procedures.

Determine possible fault causes


35/40

At the completion of this topic, you must be able to determine possiblefault causes.

When you identify a problem, you should attempt to determine its

cause. For example, you might see a temperature gauge indicating amuch higher than usual temperature. It could be that the gauge isfaulty, or that it is indicating a fault condition. If everything elseappears to be correct, you could take a temperature reading using athermometer you know is working correctly to at least identify if thegauge is faulty.

As a general rule, fault conditions will be:

a process problem such as incorrect flow rates, pressuresor fluid levels

a mechanical problem, such as a failed bearing, leaky

gland, broken shaft, blocked filter or strainer, obstructedpipe or a valve stuck in an open or closed position

an electrical problem with a:o motoro gauge or other instrumentationo control systemo heating elemento status indicator lamp, etc.


For each problem identify if the fault category is a processproblem, and mechanical problem or a electrical problemusing the drop down boxes.

If you are unable to identify the cause, you should attempt toidentify whether the fault is mechanical or electrical, or aprocess problem. The more information you can give abouta fault the better, including suggestions about the cause.

The strainer isblocked

Mechanical problem

A heating elementis not working

Electrical problem

Fluid levels areincorrect

Process problem

A valve is stuck in aclosed position

Mechanical problem


36/40

The motor hasburnt out

Electrical problem

The control panel is

not respondingElectrical problem

Pressures areoutside range

Process problem

A gland is leaking Mechanical problem

Example Scenario

You are at work one day and you notice a motor has stopped. Acheck at the switchboard for that motor can identify whether thecircuit breaker for that motor has tripped. If so, and it's within yourarea of responsibility, you would reset the circuit breaker. If thebreaker trips again you will be able to report this information, as itindicates the problem is electrical, and that it needs urgentattention.

The more experience you have with the

equipment in your area of responsibility theeasier it will be to identify causes of problemswith the equipment. It is important to attemptto identify the cause, but you should notundertake tests or undertake tasks outsideyour area of responsibility.

Workplace Activity OPS300A-73-2

Part 2:

Using the same problem from your workplace that youdescribed in the previous workplace activity, answer thefollowing question.

Question 3

Was the fault a mechanical or electrical, or a processproblem?

Add this question to the ones you have already answered


37/40

until you are instructed to send it to your tutor

Rectify problems

At the completion of this topic, you must be able to rectify problem using appropriate solutionswithin area of responsibility.

Rectify problems using appropriate solutionIn some cases you will be able to rectify a problem with an item of equipment. The type of repairsyou make must be within your scope of responsibility and skill level. In some cases, you couldneed to obtain relevant work permits and to fully isolate the equipment. as well, the work mayrequire special conditions such as:

standby personnel for confined space entry

fire spotters for welding operations personnel protective clothing

breathing apparatus

earthing connections wetting equipment to keep it cool or prevent sparks

safety harness for working in confined spaces or at heights

forced draught ventilation for confined spaces communication equipment for working in confined spaces.

All maintenance work must be carried out according to standard operatingprocedures and after the appropriate training has been carried out and assessed

for competency.

If repairs are to be carried out in a confined space, gas testing must be carried out immediatelybefore entering a confined space, and at regular intervals during the work.

Once the possible causes have been identified, solutions can be proposed.

Standard operating procedures must be followed at all times.


38/40


Part 3:Using the same example of a problem from your workplace that described in theprevious workplace activity answer the following question.

Question 4.What solution was used to rectify the problem?

Add this question to the previous three you have answered. You will be giveninstructions about when to sent them to your tutor

Follow up problems

At the completion of this topic, you must be able to follow through items initiated until finalresolution has occurred.

When work is undertaken on an item of equipment, it's important to ensure the work is followedthrough until either:

all work is completed

the work is handed over to others who take on the responsibility for repairs, etc.

After work is completed, the equipment and the work area should be inspected to ensure the taskhas been completed in terms of operations, housekeeping and safety.

All equipment should be securely bolted and not damaged. Loose bolts are a common hazardencountered when returning equipment to service. Foreign material or equipment such aswelding rods, blocks of wood or tools can be left inside a vessel and if present must be removed.Surplus equipment, rubbish, rags, scaffolding, etc, must be removed from the site before returnto service, especially flammable materials such as wood, paper or solvents.

After checks have been completed to ensure the equipment is safe and free of hazards, andapproval has been given, the equipment may be deisolated.

This could involve removing blinds, tags, etc, resettingor activating controls, alarms, interlocks and actuators,or re-energising electrical and instrument equipmentand closure of all vents and drains


39/40

Inspect the isolation log or register and check off each item as it is returned to normal duty asrequired. Check the do not operate tag register and remove tags as required.

Follow up items initiated until resolved

However problems are dealt with, and depending upon the responsibility you have for finding thesolutions, follow-up is an essential step in the process.

Even if the problem has been passed on to others to find and implement solutions, follow up isessential - this makes sure that your problem is not lost in the 'system'.


Part 4:

Using the same problem from your workplace that you described in previousworkplace activities, answer the following question.

Question 5.After the problem was rectified describe the follow up that was undertaken (such asinspections, checks, or housekeeping)

Report problems

At the completion of this topic, you must be able to report problems outside area of responsibilityto designated person.

In some cases you will not be able to solve a problem you haveidentified with an item of equipment. Or, the necessary repairsmight be outside your area of responsibility. You would thereforeneed to report the problem to a designated person.

Your report can be verbal or in writing, depending on workplace practices. In either case, it'simportant to make a complete report to give the person a full description of the problem. Include

any information you consider useful, such as:

why you think there is a fault (eg, from instrument readings or observations)

the type of fault (process, mechanical, electrical)

the effect the fault is having on the product, downstream equipment, etc

whether the fault needs immediate attention (eg, a small leak from a gland is less seriousthan an abnormal pressure or temperature)

the location of the fault (eg, a stuck valve on a manifold located near the XYZ heatexchanger).

The important thing is to always do something about a fault. Do not leave it for

someone else to report or repair.


40/40

Report problems outside of your responsibilityWhere it is clear that the problem you have found is not with your responsibility area, make surethat it is reported and passed on to the appropriate person.

The discovery and solution to problems is an essential part of good operation.

start up unit

Documents