construction

4

PlANTCONSTRUCTION

Achievingprocesssafetybycontrollinghazardsandreducingthecon-

quencesofanincidentcanbeaccomplishedbymaintainingprocessand

onsaboutthemaintenanceofprocessandequip-

r,during

theconstructionpha,thedesignfactorsthataffectprocessandequipment

rationsandmaintenance

departmentscanplayavitalroleinensuringthatequipmentintegrityis

nhelpensurethatthecon-

structioniscarriedoutaccordingtospecificationsandthattheplantwillsafely

containandcontrolthematerialsbeingprocesdunderallconditionsof

,constructionisthetimewhenoperationsandmaintenance

departmentsgatherinformationforoperatingproceduresanddataforme-

chanicalintegrityprograms.

Theroleoftheoperationsandmaintenancedepartmentscanbeextensive

ther

hand,duringturnkeynewplantconstruction,

materialprentedinthischapterappliesmainlytotherolesplayedbythe

operationsandmaintenancedepartmentsduringmajormodifications(e.g.,

theadditionofanewunit)reeofinvolvementof

theoperationsandmaintenancedepartments,asdefinedearlierinChapter2,

theconstructionpha,thedegreeofinvolvementremainsataconstantlevel

andconsistsofoversight,assistancewithinspections,anddatagatheringfor

operatingproceduresandmechanicalintegrityprograms.

FTHEOPERATIONSANDMAINTENANCE

DEPARTMENT

Therolesoftheoperationsandmaintenancedepartmentduringthedesign

nstructionstarts,theoperations

rsightrole

continuesduringconstruction,wheretheprocesssafetymanagementfocus

becomesqualityassurance—toensurethattheprocesquipmentisbuilt

accordingtodesignspecifications,thatitisasmbledandinstalledproperly,

andthatthemaintenancedepartmenthastherequiredinformation,training,

ghthe

immediateresponsibilityforqualityassurancebelongstotheprojectmanager,

operationsandmaintenancepersonnelcanprovidevaluableassistancewith

tuncommonforoperations

andmaintenancepersonnel,becauoftheirworkbackgroundandexperi-

ence,toidentifysafetyhazards,operability,andmaintainabilityproblemsthat

mayhavepasdundetectedbytheengineeringgroupsinthedesign,draft-

ing,uction

pha,theoperationsdepartmentstartsgatheringinformationfordeveloping

operatingprocedures,andthemaintenancedepartmentstartsgathering

equipmentdataforrecordkeepinganddevelopingmaintenanceprocedures.

Plantmanagementshouldmakesurethatoperationsandmaintenance

personnelareinvolvedintheplantconstructionandqualityassuranceproce-

,operationsandmaintenancepersonnelcannot

onlyhelpwiththeverificationandinspectionprocess,butalsostartlearning

aboutactivitiesrelatedtothestartup,operation,andmaintenanceoftheplant.

Manystartupandoperatingincidentsattributedtohumanerrorcanbeavoided

byinvolvingoperationsandmaintenancepersonnelduringconstruction.

icationandCoordinationwithProjectTeam

Communication(bothformalandinformal)betweentheprojectteamandthe

operationsandmaintenancedepartmentsshouldcontinueastablishedduring

lly,theprojectmanageristheoperationsand

maintenancedepartments'communications

shouldincludeawrittenscheduleofconstructionactivitiestablishedbeforeany

tiontospecifyingdatesforbeginningand

completingconstructionactivities,thescheduleshouldclearlyidentifytheduties

onstructionhasstarted,theproject

teamshouldholdregularmeetingswithoperationsandmaintenancedepartment

reprentativestoreviewthestatusofconstruction,revitheconstruction

schedule,tiontoavoidingincidents,

communicationamongthedifferentdepartmentsinvolvedreducesconstruction,

pre-startup,4-1givexamplesofconstruction

activitieswherethecoordinationofdifferentgroupscanreduceconstruction

delaysandatthesametimehelpavoidhazardoussituations.

Forexample,becauofexcellentcoordinationandcooperationbetween

theprojectteamandtheoperationsandmaintenancedepartments,amajor

expansionofaherbicideplantwascompletedtwomonthsaheadofschedule.

projectteamfoundwaystodothingsmorequicklybycoordinatingits

mportant

benefitwasthattheoperationsandmaintenancedepartmentswereableto

providetheirinputtotheprojectteamandplanpre-startupandcommission-

ingtasks.

Inadditiontotheformalcommunicationsdescribedabove,itisvery

importantthatinformalcommunicationsbetweentheprojectteamandthe

operationsandmaintenancedepartmentsbemaintainedthroughoutcon-

jectmanagershouldensurethattheprojectteamisfamiliar

areasupervisor(bothoperationsandmaintenance)shouldregularlybein

touchwiththeconstructionsupervisortoavoidschedulingproblemsand

TABLE4-1

ExamplesofConstructionActivitiesThatMayRequireCoordinationbetween

theConstructionTeamandtheOperationsandMaintenanceDepartments3

ConstructionActivity

cavation.

entfoundations.

supports.

ticdevicesandtubing.

icalwireandcabletray.

lationofcontrolpanels,distributedcontrol

systems.

lationofallprocessconnectedelectronic

transmittersandnsordevices.

lationofcontrolvalvesandmeterruns.

lationofreliefvalvesandrupturediscson

vesltc.

erencesbetweenpipeandconduitalong

piperacksandbuildingwallsorceilings.

-instoexistingvesls,piping,andequipment.

Operations

Involvement

Participatory

Supportive

Supportive

Supportive

Supportive

Participatory

Supportive

Minimal

Minimal

Participatory

Lead

Maintenance

Involvement

Participatory

Participatory

Participatory

Supportive

Supportive

Supportive

Supportive

Supportive

Supportive

Supportive

Lead

aThelevelsofinvolvementshowninthistableusuallydependonwhetheritisagreenfieldcon-

derneedstomakeaconsciousdecisionof

whatthelevelsofinvolvementare.

ereisanunresolvedconcernorconflict,the

ossibleeffortshouldbemadeto

avoidthe"usversusthem"attitude.

Inadequatecommunicationbetweentheprojectteamandtheoperations

mple,a

constructionprojectinvolvedtheinstallationofadditionalairdryercapacity

neratetheadditionalcapacity,asteamline

eareaforemanand

theconstructionforemanknewabouttheworkbutmiscommunicatedabout

struction

crewcutintoanactivehigh-purityoxygenline,

theareaforemanandconstructionforemanhadbeencommunicatingprop-

erly,rationsandmaintenance

departmentsshouldhavealeadroleinauthorizingatie-intoanexisting

ationsormaintenancedepartmentreprentativeshould

havebeenprentatthesitetopointoutthecorrectlineandensurethatthe

workcouldbeperformedsafely.

lofSpecificConstruction-RelatedActivities

InadditiontocheckingthatconstructionisdoneaccordingtotheP&IDsand

otherspecifications,theoperationsdepartmentshouldalsoberesponsiblefor

personnelandequipmentsafety,allprocesstie-ins,andallconstruction

permits(i.e.,workpermits,hotworkpermits,weldingpermits).Forexample,

ifhottappingisneeded,theoperationsdepartmentwilldeterminetheappro-

uctiontechniques,

ontheotherhand,

example,theriggingforliftingequipmentaboveoperatingequipmentshould

situation,the

operationsdepartmentwoulddevelopcontingencyplansforpotentiallyhaz-

4-2

prentssomeoftheconstruction-relatedactivitieswhenoperationsand

maintenancestaffshouldhaveacertaindegreeofcontrol.

tionofEquipmentInstallation

Theinspectionandtestingofmajorequipmentatthefactoryiscriticalandis

r,theinspectionofequipment

asitisinstalledisalsoimportanttoensuringtheoverallintegrityoftheprocess

,theoperations

andmaintenancestaffhelptheprojectteamwithqualityassuranceandthe

,theinspectionsallowoperationsand

maintenancesupervisorstogathertheinformationneededtomaintainproc-

mple,

TABLE4-2

ExamplesofConstructionActivitiesControlledbythe

OperationsandMaintenanceDepartments

Electricalwork

Generalrulesforthesafeperformanceofelectricalworkareestablishedbymaintenance

icalareaclassificationshouldbeknownbyallpersonnelperformingelectrical

nauthorizationtoproceedwithworkinoperatingareas

shouldbeobtainedfromtheoperationssupervisor.

Pneumatichammersandchils

Maintenancedepartmentmayhavespecificguidelinesforusingpneumatichammersandchils.

Ifspecificguidelinesdonotexist,operationsandmaintenancepersonnelshouldensurethat

appropriateprecautionsaretakentoavoidhazardsassociatedwithflyingscaleorchipsandfrom

toolsandbitsflyingfromthegun.

Hottapping

Specificapprovaloftheoperationssupervisorandappropriatepermitsshouldbeobtainedbefore

etobehottappedshouldbepositivelyidentifiedandthe

operationssupervisorshouldmarkthespecificpointonthelinewherethehottapistobemade.

Theoperationssupervisorshouldalsobesatisfiedthatthemetalthicknessofthelineissufficient

lternateweldingmethodisud,the

maintenancesupervisorshouldapproveit.

Scaffolds

Itisimportantthatscaffoldsbeadequatefortheintendeduandthattheworkmenengagedin

buildingandusingscaffoldsbethoroughlybriefedinandaboutpotentialhazardswithinthearea

ldsshouldnotblockemergencycontrolsorescaperoutes.

Hotwork

Theopertiesthat

mightreleahydrocarbons(e.g.,samplingorgauging)intheareashouldnotbeperformedunless

approvedbytheindividualwhosignedthehotworkpermit.

Confinedspaceentry

Proceduresions

shouldverifytheconditionsandissuepermitsforconfinedspaceentry.

theoperationsdepartmentrequiresinformationonthelocationandconfigu-

rationofequipment,controls,andindicatorsoneachpieceofequipmentto

ntenancedepartmentre-

quirestheknowledgeofasmblyprocedures,valveandpackingtypes,gasket

material,instrumentation(frommaintenanceviewpoint),manufacturersmodel

number,

4-3listssomemajorpiecesofequipmentandincludesitemsthatshouldbe

inspectedbyoperationsandmaintenancestaffduringconstruction.

TABLE4-3

OperationsandMaintenanceItemsofInterestforMajorEquipment

Fabrication,Construction,andInstallation

MajorEquipment

Boilers

Compressorsand

blowers

Drivers(steam

turbine,gangine,

gasturbine)

ElectricMotors

Electricaldistribution

system

OperationsandMaintenanceItemsOfInterest

Fuelgasknockoutdrum

Flameoutprotection

Blowdown

Instrumentation(firingcontrol,waterlevelcontrol,pressure)

Safetyvalves

Blockvalvelocations

Feedwatersystemsandtreating

Lubrication

Automaticshutdowns

Emergencyshutdown

Surgecontrol

Vibrationmonitor

Indicatinginstruments

Crankcavent

Grouting

Materials—cylinder,valves,wheels,ca,shaft

Packingvent

Lubricationsystem

Overspeedtrip

Automaticshutdowns

Instrumentation

Vibrationmonitor

Safetyvalves

Crankcavent

Grouting

Electricalclassification

Propergrounding

Lubrication

Breakersandheaters

Grounddetector

Areaclassificationsandequipmentu

Grounding

Sealing

Vulnerabilitytofire

Uninterruptiblepowersupplysystem,emergencyelectricalsystem

Communicationsystems

Motorcontrolcenters,identificationofstarters

TABLE4-3(Continued)

OperationsandMaintenanceItemsofInterestforMajorEquipment

Fabrication,Construction,andInstallation

MajorEquipment

Firedheatersand

furnaces

Heatexchangers

Instrumentationand

wiring

Loadingracks

Pressurevesls

OperationsandMaintenanceItemsOfInterest

Flameoutprotection

Fuelgasscrubbers

Snuffingandpurgingsteam

Curbwallsanddrainage

Fireproofingofsupports

Tubemetaltemperatureindicators

Remoteshutdown—fuelgasandprocesslines

Flamepattern

Materials

Layout,congestion,andexposure

Maintainability(roomforcleaningandmaintenance)

Leakageandtubefailureprotection

Thermalexpansion

Airfailureconsiderations(airopenorairclo)

Powerfailure

Emergencypowersource

Valveaction(clooropen)

Emergencycontrol

Suitabilityofinstrumentsforrvice

Cabletray;properbondingandwiring

Calibrationandtuning

Conditionafterconstructionactivities

Winterizing

Loadingrates(opendome)

Grounding,bonding,andinsulation

Downspouts(opendome)

Loadingconnections

Ventanddrainfacilities

Emergencyshutoff

ASMEratingsuitability

Emergencyreliefvalves

Ventinganddraining

Safeterminationofemergencyreliefdischarges

Blinding

Supportfireproofing

Smallpipeandgaugeconnections

Winterizingdrawoffs

Continuedonpage66

TABLE4-3(Continued)

OperationsandMaintenanceItemsofInterestforMajorEquipment

Fabrication,Construction,andInstallation

MajorEquipment

Pumps

Tankage

OperationsandMaintenanceItemsOfInterest

Materials

Layout,congestion,andexposure

Mechanicalals

Vibration

Drainsandvents

Instrumentationandcontrols

Valvingarrangements

Sparingofpumps

Atmosphericconeroof

Ventcapacityandtypes

Weakenedroofam

Equipmentindike

Waterdraw-off

Overfillingprotection

Spacing(betweentanks,otherequipment,propertyline)

Floatingroof

Controlofroofdrainage

Valvedpipingmaterialinsidedike

Miscellaneousdrumsandsmalltankage

Ventingcapacity

Fireproofingofsupports

Pressurizedstorage

Safetyvalvearrangementandimpingement

Fireproofingofsupports

Fireproofingofveslsorwaterdeluge

Smallpipeconnections

Caugeglass

Vacuumbreakers

Properinertgasblanketing

ALSOFCONSTRUCTION

Mechanicaldesignrestrictionsarelargelydeterminedbythematerialsof

alsarechonfortheireaoffabrication,abilityto

withstandrviceconditions,compatibilitywithotherconstructionandproc-

essmaterials,aterials

ot

addition,documentationaboutthepropermaterialsofconstructionisalso

esntialforfuturereferenceandplantchanges.

Animproperuofmaterialsofconstructioncanleadtoincidentsthat

ntthatwasproducing

hydrogenbythepartialoxidationofcrudeoil,acontrolvalveonthereactor

valvewasadifferentgradeofsteelthanhad

hreemonthsofrvice,hydrogenembrittle-

fireand

cidentcouldprobablyhave

beenavoidedbythepropercontroloftheuofmaterialsofconstruction.

Theoperationsandmaintenancedepartmentsshouldbesatisfiedthatthe

materialsofconstructionudarethospecified,eventothepointofverifying

structionteammayconduct

testsasspecifiedintheconstructionbid,todeterminethepropertiesofmaterials.

First-andcond-linesupervisorsshouldensurethatproperdocumentation

iskeptonthematerialsofconstruction,yassur-

anceprograms,insomecasrequiredbygovernmentalregulations,can

probablybemanagedmosteffectivelybythemaintenancedepartment.

Athoroughinspectionofequipmentbyoperationsandmaintenance

personnelduringplantconstructionisoneofthemostimportantstepsin

operationsandmaintenancestaffprovidecriticalsupportinverifyingthat

constructionisperformedasspecifiedbydesign(e.g.,levelingweirsduring

theconstructionofdistillationcolumns).Thematerialsofconstructiondocu-

mentationthatshouldbecollectedincludesmillcertificationreportsand

verificationsthatthecorrectmaterialshavebeenud,aswellasanyresults

oftestsdoneonthematerials.

EQUIPMENTFABRICATIONANDINSPECTION

Customequipmentfabricationrequiresadditionaldocumentationsuchasa

materialslist,apartslist,partsdrawing,

thoroughinspectionofcustomequipmentispeciallyimportanttoensure

stom-builtequipmentisinvolved,

operationsandmaintenancereprentativesshouldperiodicallyobrvethe

llenabletheoperationsstafftounderstand

theequipmentandincorporatethisknowledgeintoappropriateoperating

procedures,andthemaintenancestaffwillbebetterabletoaddressasmbly

mple,equipmentwithspecialinternalconfigu-

rationsshouldbeinspectedintheshop;thisincludeslargecompressors,large

steamturbines,specializedreactors,e

1Federalregulations[29CFR1910.119(j)]intheUnitedStatesrequirestheimplementationofa

qualityassuranceprogramtoensurethatequipmentasitisfabricatedissuitablefortheprocess

riatechecksandinspectionsmustbeperformed

toensurethattheequipmentisinstalledproperlyandisconsistentwithdesignspecifications.

Also,thequalityassuranceprogrammustensurethatmaintenancematerials,spareparts,and

equipmentaresuitablefortheprocessapplicationforwhichtheyareud.

beneficialforoperatingandmaintenancepersonneltoattendshopinspections

andtestsofcriticalequipment,forexample,theinspectionofshop-installed

columnorveslinternals.

Aninspectionofcriticalequipmentduringconstructioncanidentify

mple,duringanasmblyinspection

ofamultistagecryogenicpump,amaintenanceforemanobrvedthatthe

uentinvesti-

gationrevealedthattheimpellershadbeencastinreverbecauofanerror

demonstratestheimportanceof

involvingtheoperationsandmaintenancedepartmentsintheinspection

process.

NSTALLATION

Pre-startupandcommissioningactivitiesusuallyinvolvethefinalinspection,

testing,andcommissioningofallthepiping,vesls,equipment,andcontrols.

However,manyproblemscanbeavoidedbycarryingoutconstructioninspec-

tionsthatarefocudonoverallplantsafety,operability,maintainability,and

ionsandmaintenancepersonnelcanverifythattheequip-

mentisinstalledaccordingtothespecificationsandmanufacturer'sinstruc-

nmakesurethatthepipingandinstrumentsareinstalled

4-4isachecklistofitemsthattheoperations

andmaintenancedepartmentsmayinspectwhileconstructionisinprogress.

Inadditiontopiping,theinstallationoftheprotectionsystemsshouldbe

asastartupteamisformed,theoperationsandmainte-

nancepersonnelthathavebeenperformingconstructioninspectionsshould

beassignedtothestartupteam,whichwillensurecontinuityoftheinspection

processandprovidethestartupteamwithpeoplealreadyfamiliarwiththe

processandequipment.

Installation

Surveysshowthatthefailureofpipingisafrequentcauofprocessplant

ingtoKletz^mostpipingsystemfailuresarecaudbythe

pipingnotbeinginstalledaccordingtodesignspecificationsoraccordingto

goodengineeringpractice,

preventionofsuchfailuresrequiresmoredetailedspecificationsandathor-

ionsandmaintenancestaffcan

4-5isalistof

pipingconstructionandinstallationitemsthatshouldbechecked.

Significanthazardsaresometimescaudbyeminglyunimportant

mple,inthestorageofalow-boilinghydrocarbon'2',

onlylargegatevalveswereinstalledsinceitwasbelievednowaterwouldget

TABLE4-4

ExamplesofOperationsandMaintenanceInspectionItems

duringConstruction

ouldbedeterminedduring

r,designerrorscanoccur,sothisshouldbecheckedaccordingly.

ocatinginstrumentsinareasofhighpersonneltraffic.

essuregaugesanddialthermometerstowardtrafficlanesforeasyobrvationby

operators.

lassfrontsoninstrumentitemswhereheavytrafficorworkmightcaubreakage.

reglassandidentificationplatesarecoveredbeforepaintingisdoneinthevicinity

ofinstruments.

reallnecessarycalibration(i.e.,reliefvalves,pressuretransmitters,etc.)iscompleted

beforeinstallationunlessin-placecalibrationisrequired.

nstallin-linedevices(e.g.,orificeplates,positivedisplacementsmeters,rotameters,

etc.)untillineshavebeenflushed.

unpneumatictubingtooclotohotsurfaces.

ocateinstrumentandcontroltubingwheretheywillbesteppedonorotherwi

damaged.

rethatelectricalinstallationscomplywiththeclassifications.

torageofsafetyapparatus(e.g.,breathingapparatus),esntialancillariesandtools

(e.g.,laddersandsteps),solventsandcleaningmaterials,aswellaswastematerials(until

disposal),shouldbeprovided.

ceneededformaintenanceoperationsshouldbetakenintoaccount,andchecked

thatitdoesnotobstructfireexitsorencroachonbusypassageways.

addersorstairsshouldbeprovidedtogiveaccesstooverheadworkpointsthatrequire

theprenceofanoperatorormechanic.

ctricalcablesandapparatusshouldbeprotectedagainstmechanicaldamage,heat,

water,chemicalattack,andunauthorizedaccess.

bleattachmentpoint(beam,eyebolt,etc.)shouldbeprovidedabovethetopmanhole

orotheropeninginvesls,hoppers,leachainblocktobeudtogetequipmen

inoroutortowinchoutaninjuredperson.

s,heatexchangers,beprovidedwithameansofpositiveandcomplete

isolation(e.g.,blindflanges)sothattheycanbecompletelyisolatedduringinternalinspection

andmaintenance.

ascontainingflammableliquidsshouldbeelectricallybondedandgrounded,including

steel-framedbuildings.

nitsshouldbecleanandfreefromobstruction.

scontactsurfacesshouldbeasspecified(correctmaterialsofconstruction).

entshouldbeleaktighttospecifiedtestpressures(particularattentionshouldbegiven

tomechanicalals).

htnessandflowofsteamtracingshouldbechecked.

giclaggingrequirementsshouldbechecked.

ndinstrumentlabelsshouldbeclear,visible,andlegible.

TABLE4-5

ExamplePipingConstructionandInstallationChecklist

-andhigh-pressurealarmsshouldbeinstalledinpiping,asappropriate.

cksshouldhaveanacceptedleveloffireprotectionand,ifnecessary,sprayprotection

forpipinginracks.

expodtocorrosiveatmospheresshouldbepaintedorotherwiprotectedtoprevent

thedeteriorationofwallthickness.

remergencypersonnelshouldbeabletoisolatepipingbyclosingvalves.

cas,acomprehensivecolorcodingsystemof

pipesandvalvesmaybeuful.

uchascirclebends,doubleoffts,andothergeometriesinvolvingcomplexgeometry

shouldbeavoided.

riatepipelugsupports,piperestraints,guides,andanchorsshouldbeud.

installationshouldmatchP&IDsandisometricdrawings.

renecessarysampleconnectionsforroutinesamplesorstreamanalyzers?

-pointdrainsshouldbepositionedinplacessothatthemaximumamountofwatercan

bedrainedafterhydrostatictestingorforfuturemaintenance.

cationoftheuofappropriatematerialsofconstructionshouldbemade.

reprovisionstoaccommodateexpansionandcontractioninpipelines?

sshouldbelabeledclearlytoindicatedifferentmaterials.

eofflowreductions,however,waterwassuspected

openedthe2-inch

drainvalve,nothingcameoutatfirst,y,

triedtoshutthevalve,itstuck,

probablyfromhydratesformedasaresultoftherefrigerationcaudbythe

ratorwasovercomebythehydro-

adbeenrecentrainsandthedikeareacontainedabout

,

therewerealotofsafetyerrorsinthisca,butasmallerdrainvalveand

contingencyprocedurestocopewithhydrateformationcouldhaveprevented

atragedy.

re-Relief/VentCollection

Verifyingthecorrectinstallationofpressure-reliefdevices(i.e.,controlvalve,

springorpilotoperatedreliefvalves,rupturesdiscs)isanecessarypartof

essorequipmentintegrityiscompromid,the

favoredmitigationactionisactuationofthepressureindicatorcontrolvalves

andventing;however,incertaincircumstances,thereliefvalveortherupture

ryimportantthatallpressure-re-

lievingdevicesareinstalledproperly,withtheshippingpackingremoved

yissuestorememberabouttheinstalla-

tionofpressure-relievingdevicesare:

Infoulingrvice,sometimesrupturediscsareinstalledbelowrelief

valvestopreventfoulingandinterferencewiththereliefvalve'sopera-

ntsoftherupturediscandthereliefvalveshouldbe

comparedforcompatibility.

Forpilot-operatedreliefvalves,thensortubingshouldruntothe

lowsforeasytestingandinspectionofthereliefvalve.

Blockvalves(ifud)forallpressure-relievingdevicesshouldbealed

open.

Thetrippointofthereliefvalveshouldbeindicatedonthenametag.

Thespecificationsonreliefdevicefittingsshouldbecheckedvery

4-1showstheappropriatespecificationsonfittingson

nmistakesometimes

foundistheinstallationofa150ANSIflangeatAinsteadoftheproper

600ANSIflange.

Togainsomeredundantsafetyadvantage,reliefvalvesandrupture

ecas,theinstallation

shouldbeasshowninFigure4-2.

Allpressure-relievingdevicesareinspectedbythemaintenanceshops

revariationsof

thisprocedure;however,inmostcas,themaintenancedepartmentplays

aleadroleininspectingandvalidatingpressure-relievingdevices.

FlangeA

Rupturedisc

150ANSI

600ANSI

600ANSI

lationofrupturedisc

Vesldesigned

for1440pslg.

NormaIoperatIng

pressure:1000

psJa.

ReIiefvaIve

tat1200

pslg

Rupturedisc

tat1400

psIg

lationofreliefvalveandrupturediscinparallel

afetySystems

Dependingontheprocessplant,thenatureofoperations,theverityof

operatingconditions,andthesurroundingenvironment,varioussafetysys-

fetysystemsmayconsistofprotection,detec-

tion,esofsuchsystemsarefire,gas,andsmoke

detectors,fireprotectionequipment,ghmany

ofthesafetysystemsarecommontoanumberofplantsites,theactual

ionsandmaintenanceperson-

nelshouldwitnesstheon-sitetestingofsafetyprotectivesystemstobecome

familiarwiththeiroperation.

ENTRECORDKEEPING

Equipmentrecordkeepingisntialforlong-termprocessandequipment

,somegovernmentregulationsrequirethatmechanicalinteg-

nstruction

begins,themaintenancedepartmentshouldstartaccumulatingdataforthe

nformationcollectedshouldbefiledinaparate

y,eachfoldershouldincludeatleasttheinformationshownin

2IntheUnitedStates,DepartmentofLaborregulations131[29CFR191O.U9(j)]containspecific

guiryofthe

tionsappearsinAppendixA.

TABLE4-6

MinimumDataNeedsforEquipmentRecordkeeping

lydrawings.

ists.

onandmaintenancemanuals.

gs.

pondencebetweenthemanufacturerandtheprojectteam.

ications

(a)Specificationsheetwithallthename-platedata.

(b)Materialspecificationofwearingparts.

(c)Partnumbersandspecifications.

insprescribingcorrectmethodsofperformingunusualordifficultrepairs.

gslistinginterchangeableparts.

iles,alongwiththeotherinformationanddatapertinentto

theprocessanditquipment,shouldbestoredinalocationthatwillbe

accessibledayandnighttoalloperationsandmaintenancepersonnel.

Integrateddocumentmanagementsystemsareanewtrendinthechemi-

aldatabacontainingallplantdocumentation,from

processdrawingstoconstructionmemoranda,isthegoalofmoderncom-

arietyofthesystems

arecurrentlyavailable,fromthesimplesystemforasmallplanttoalocalarea

sareusingCD-ROMdevicestoprovide

detailedconstructionandmaintenancemanualswithgraphicsandsometimes

lessofthedatamanagementsystemsud,

theoperationsandmaintenancedepartmentsshouldhaveknowledgeofand

tknowledgeofandaccesstotheequip-

mentdata,itisimpossiblefortheoperationsandmaintenancedepartments

toensurethecontinuedintegrityoftheplantprocessandequipment.

Whenawidevarietyofplantdocumentationsystemsareavailable,two

thingsarenecessaryforsuccessfulinformationmanagement:

•Theinformationshouldbewidelyavailableinaneasy-to-uand

,trainingoperationsandmaintenance

staffindocumentaccessiscritical.

•Theauthorizationtochangethemasterdocumentinthesystemshould

alsobetightlycontrolledandasystemtoinformmanyursofchanges

isalsoveryimportant.

Y

Theroleofoperationsandmaintenancedepartmentsintheexecutionof

specificactivitiesduringthevariousphasofthelifecycleofaplantmay

rangefromaminimaltoaleadrole,r,as

theplantgoesthroughthedesignpha,theconstructionphaandoninto

thepre-startupandcommissioningphas,theoverallparticipationofopera-

rallpartici-

pationoftheoperationsandmaintenancedepartmentsduringthedesign

phaisminimal,althoughtheremaybecertainspecificactivitiesofthedesign

phainwhichoperationsandmaintenancedepartmentshaveamoresignifi-

reeofparticipationofthedepartmentsremainsconstant

duringtheconstructionphaandconsistsmainlyofoversight,assistance

withinspections,andgatheringdataforoperatingproceduresandmechanical

integrityprograms.

NCES

,T.A."SafetyAspectsofPressurizedSystems."IMechE,1981.

,E."SafetyinProcessandMechanicalDesign."ChemicalEngineering,Aug.

17,1964.

sSafetyManagementofHighlyHazardousChemicals;ExplosivesandBlasting

Agents;FinalRule,mentofLabor,OccupationalSafety

andHealthAdministration,Washington,DC,February24,lRegister,

Vol.57,No.36,pp.6356-6417.