Guidelines for Preparing Process Equipment for Maintenance and Return to Service

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.

Table of Contents:
List of Figures xii  List of Tables xiii List of Case Studies xiv Acronyms and Abbreviations xvi Glossary xix Acknowledgments xxvii Dedication xxix Foreword xxxi Preface xxxii 1 Introduction 1 1.1 Purpose and Scope of the Book 1 1.2 Key Definitions Relevant to Preparing Equipment for Maintenance and Return to Service 3 1.3 Overview of the Main Focus Areas 3 2 Regulation and Process Safety 5 2.1 Regulatory Aspects 5 2.2 Company Standards and Safe Systems of Work 6 2.3 Process Safety and Personal Safety 8 3 Understanding the Hazards 11 3.1 Information Requirements-Process Safety Information 11 3.2 Equipment Hazards 12 3.3 Energy Hazards 17 3.4 Simultaneous Operations 24 3.5 Human Factors 24 3.6 Frequently Encountered Issues when Preparing Equipment for Isolation 25 3.7 Summary 26 4 Planning for Isolation and Decontamination 27 4.1 Plan Considerations 27 4.2 Risk Assessment 29 4.3 Isolation/Decontamination – Which Comes First? 35 4.4 Planning The Energy Isolation 36 4.5 Planning for Decontamination and Decommissioning 39 4.6 Disposal of Chemicals from Decontaminated Processes 43 4.7 Planning for Return to Service 43 4.8 Changing Plans 46 5 the Decontamination Plan 47 5.1 Documented Plan 47 5.2 Phase of Decontamination 49 5.3 Managing the Decontamination Hazards and Risks 50 5.4 Training for Decontamination 53 5.5 Difficult Decontaminations 55 5.6 Moving Decontaminated Equipment 57 5.7 Checklists and Equipment Identification 57 6 Executing the Decontamination Plan 59 6.1 Sharing the Plan 59 6.2 Tracking the Plan 60 6.3 Completing and Documenting Execution of the Plan 63 6.4 Complex Decontamination Plans 64 6.5 Equipment Readiness for Energy Isolation 66 6.6 Summary 66 7 Isolation and Decontamination Plan Examples 69 7.1 Isolating/Decontaminating Lines with Toxic Materials using “Double Block and Bleed” 69 7.2 Isolation/Decontamination for Vessel Entry 73 7.3 Isolation for Longer Term/Mothballing 77 7.4 Isolating/Decontaminating Butyl Lithium Storage Systems 78 7.5 Example – Isolating/Decontaminating a Toluene Diisocyanate Reactor Train 85 7.6 Summary 92 8 Overview of Energy Isolation 93 8.1 Degrees of Isolation 93 8.2 Human Factors in Energy Isolation 95 8.3 Designing for Energy Isolation 96 8.4 Locking and Labelling 98 8.5 Documenting Energy Isolation 99 8.6 Chemical Process Isolation 101 8.7 Electrical Isolation 101 8.8 Mechanical, Potential and Natural Energy Sources 103 8.9 Nuclear Radiation 103 8.10 Summary 104 9 Written Energy Isolation Plans (eip) 105 9.1 De-isolation, Testing, and Restart Considerations 106 9.2 Risk Level 106 9.3 Documentation - Safe Work Permit and EIP 109 9.4 Piping and Instrument Diagram (P&ID) Symbols for Process Isolation 110 9.5 Forms and Types of Energy Isolation 112 9.6 Lock – Tag - Try 114 9.7 Final Verification Before Release to Work 114 9.8 First Line Break 116 9.9 Monitoring Isolations 117 9.10 Summary 118 10 Specific Isolation Requirements 119 10.1 Process/Instrument Isolation 119 10.2 Electrical Isolation 120 10.3 Mechanical and Potential Energy and Natural Energy Isolation 122 10.4 Nuclear Radiation 123 10.5 Boundary Isolation 124 10.6 Specialized Isolation Techniques 124 10.7 Field Verification and Changes to Isolation 125 10.8 Summary 125 11 Reversing the Isolation Plan 127 11.1 Job Completion and Transfer of Equipment Ownership 127 11.2 De-isolation Procedure 127 11.3 Process De-isolation 130 11.4 Vents and Drains 132 11.5 De-isolation of Other Sources of Energy 132 11.6 Cleanliness 132 11.7 Bolts, Flanges, and Gaskets 133 11.8 Changes to Isolation Boundary 133 11.9 Summary 133 12 Recommissioning 135 12.1 Checks for Debris 137 12.2 Cleaning and Flushing 138 12.3 Purging 138 12.4 Leak/Pressure Testing 140 12.5 Functional Checks 144 12.6 Walk the Line (WTL) 146 12.7 Delayed Return to Service 147 13 Pre-startup Safety Review 149 13.1 PSSR and Returning Equipment to Service 149 13.2 PSSR Overview 152 13.3 PSSR Example: Short Form 152 13.4 Summary 156 14 Equipment Startup 157 14.1 Participation and Communication 157 14.2 Specific Startup Issues 158 14.3 Startup of Mothballed Equipment 161 15 Conclusion 165 Appendix A: Work Permit 167 Appendix B: Walk the Line 171 Appendix C: Decontamination Certificate 177 Appendix D: Long Form for Higher Risk/Complex Pssr 179 References 189 Index 197

About the Author :
The Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology since 1985. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over one hundred books in its process safety guidelines and process safety concepts series. Also, CCPS has helped develop over a hundred courses, including 33 training modules in its Safety in Chemical Engineering Education (SAChE) series. CCPS is supported by the contributions and voluntary participation of more than 225 companies globally.