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Plant Check-Out
For a normal start-up any interdependent systems should be online or in the
appropriate state for this start-up procedure. For example, if a system being
started is part of a flow stream, the upstream and downstream systems should
be online or pressurized and ready to deliver or receive product.
Safety issues
Work plan
Valves line-up
Purge requirements
Safety Equipment
8. Instrumentation
9. Catalyst/Chemicals Inventory
Valves on snuffing steam are located remote from the heater, with
drain valves and steam traps upstream of final block valve for
condensate removal.
Weep holes provided in snuffing steam lines at low points are clean.
Heater instrument connections and sampling connections are open not filled or covered with refractory.
Fuel gas, fuel oil and pilot burner tips are clean and oriented properly.
Burners are properly mounted with clearance for firing and removal.
Damper is free to move fully open and closed; its position indicator is
correct both at the stack and at the damper control.
If extended surface elements are allowed, the bottom three or more rows
of convection tubes must be bare.
External Inspection
Explosion doors located such that heater gases will not flow towards
process equipment and platforms.
Isolation valves on snuffing steam are located remote from the heater,
with drain valves and steam traps upstream of final block valve for
condensate removal. Weep holes provided in snuffing steam lines at low
points.
On/Off slide valves on suction lines are free to move fully open and
closed.
Fuel lines have battery limit block valves which are remote from the
heater and easily accessible.
Fuel oil piping and its steam tracing are correctly arranged.
Fuel oil lines at burner valves are correctly piped with steam
crossovers. All steam lines have adequate traps and condensate
drains.
Shutdown solenoids for fuel shutoff valves have been set properly.
Vessels
Mesh blankets and outlet screens: size, location, levelness, suitability of fit
(no bypassing allowed), metallurgy of blanket, support, tie wires, and
grids.
General
The vessel should be clean (free from trash) and should not have
excessive mill scale.
External Inspection
Manways and nozzles: location, size, flange rating and finish, metallurgy,
with proper gaskets, nuts and bolts.
Piping:
Filters
For filters, the same checking as for the vessels must be completed. In plus,
check if:
-
The isolation is in according with the project specification and with the
vendor requirements.
Nozzle size, flange type, rating, facing and metallurgy; vent and drain
connections.
Motor switches accessible from grade and located near the exchanger.
Tube fin surfaces are in good condition with no construction debris on top
of the fins.
Pumps general checks. The following items should be checked for all
pumps:
Grounding devices.
Restriction orifices (if required) present in seal flush manifold piping are
correctly installed.
Field Inspection
The following items should be checked in the field:
Single strand steam tracing on the bottom of suction lines and snubbers,
to
project
specifications,
location,
Instruments:
All instruments should be checked as soon as possible so that any malfunctions
or other faults can be detected early. The instrument checkout should include
the following items:
Positioner calibration
All orifice plate bores should be measured, recorded and compared with
required sizes. The orifice plates should also be checked to see if they were
counterbored wherever required. After hydrotesting and water flushing have
been completed, the orifice plates can be installed.
Piping
The following items must be checked to ensure conformity to the project design
specifications:
Flanges: rating, facing, and metallurgy; type (typically, 2" and smaller
are socket weld, 2%2" and larger are weld neck flanges).
Valves: rating and metallurgy (body, trim, seats, etc.); packing; seat
inserts; bonnet gaskets; grease seals; socket-weld or flange type,
rating and facing; installed in correct direction of flow; lubricant
provisions; gear operators; extended bonnets; stops; ease of
operation.
Bolting: stud or machine bolts; bolt and nut metallurgy; bolt size.
Gauge glasses:
Lever requirement.
General:
Utility systems within the battery limit should follow all relevant
pipe
class specifications in the same detail required for process
lines.
expand.
lines.
High point vents and low point drains should be installed where
necessary.
Catalyst/Chemical Inventory
Catalyst
It must be verified that sufficient quantities of catalyst, catalyst support material,
and other materials (such as ceramic fibre rope, etc.) are on site, in good
condition, and properly stored (for example, in drums, indoors, and on pallets to
prevent contact with moisture).
It must be verified that all equipment required to load the catalyst is on site and
in good condition.
Consider estimated quantities and detail spec
Chemicals
It must be verified that the proper type and quantity of chemicals (such as
inhibitors, sulfiding agent, soda ash, etc.) are on site and properly stored.
5.1.1
Operational Checks
The plant operator has to make several checks:
Action
1
Confirm that all construction and repair work on the system is completed.
Confirm that systems are isolated from any of the maintenance activities.
Confirm that all permits and maintenance checklists are closed out.
Confirm that the drain, vent, and bleed valves are in the closed position.
Confirm that the blinds and flanges are removed and documented.
Confirm that energy isolation has been removed. Follow the Safe Work
Procedures Manual (Lock Out / Tag Out)
5
6
Confirm that the safety and fire fighting equipment is in place, operational, and ready for use.
5.1.2
Maintenance Checks
Action
1
Ensure that the control valves, Blow Down Valves, Shut Down Valves and Emergency Shut Down
Valves are stroked to confirm that the valves are operating correctly.
Confirm that Restriction Orifices (RO), Non Return Valves (NRV), Spacers Rings (SR), Spectacle
Blinds (SB), Strainers and Spade points are correctly installed.
Confirm that electrical power is connected and tested for any necessary equipment.
5.2
5.2.1
Instrument Air
Most often, during maintenance activities, Instrument Air system is kept in
service with the specific instruments working.
Only in case of specific works on the system, it is necessary to put the header
in service as follows:
Action
5.2.2
Isolate all users turning closed the spectacle blinds or using removable blinds where
required
Remove FT-072 orifice plate. .(if some piping work has been done on the line upstream
FT)
Turn open BL spectacle blind and remove the final blind flange of the header
Blow the header until the air coming out from the end flange is clean
Reinstall FT-072 orifice plate and final blind flange of the header
Plant Air
Most often, during maintenance activities, Plat Air system is kept in service as it
might be useful for maintenance works.
Only in case of specific works on the system, it is necessary to put the header
in service as follows:
Action
5.2.3
Remove FT-071 orifice plate. (if some piping work has been done on the line upstream FT)
Blow the system until the air coming out from hose connections is clean
Nitrogen
Most often, during maintenance activities, nitrogen system is kept in service
even if isolated (blinded) at equipment connections.
Only in case of specific works on the system, it is necessary to put the header
in service as follows:
Action
5.2.4
Isolate all users turning closed the spectacle blinds or using removable blinds where required
Remove FT-065 orifice plate.(if some piping work has been done on the line upstream FT)
Turn open BL spectacle blind and remove the final blind flange of the header
Blow the header until the nitrogen coming out from the end flange is clean
Reinstall FT-065 orifice plate and final blind flange of the header
Blow all branches to users by disconnecting, if necessary, at the spectacle blinds before the
user connections
Utility Water
Utility water is very seldom put out of service as it may be functional to
maintenance activities. In case of isolation and maintenance act as follows:
Action
5.2.5
Remove FT-075 orifice plate (if some piping work has been done on the line upstream FT).
Wash header and lines from BL to all hose connections until water is clean
Drinking water
Drinking water should never be put out of service as it feeds safety showers
and eyebaths.
In case of isolation and maintenance act as follows:
Action
1
Remove FT-076 orifice plate (if some piping work has been done on the line upstream FT)
Wash header and lines from BL to showers and eyebaths until water is clean
5.2.6
Cooling Water
Cooling water supply and return headers are seldom put out of service.
In case of isolation for maintenance act as follows:
Action
5.2.7
Remove FT-066 orifice plate .(if some piping work has been done on the line upstream FT)
Isolate all user inlets and outlets (coolers, pumps and compressors cooling systems)
Close user valves (line block valve upstream of 33-FV-042 and, 33-TV-143 assembly)
In case of cleanliness doubts sample BFW from TV upstream drains and check for iron
presence
In case of maintenance of the header itself, it is better to wash the system with
utility water, (through temporary connections) from BL to the end of the header
(removing FT orifice plate and the blind flange at the end) to minimize BFW
losses and safety problems (BFW is hot, at high pressure and more expensive
than UW).
MP Boiler Feed Water
MP BFW header is normally put out of service just by closing isolation valve at
BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action
5.2.8
In case of cleanliness doubts sample BFW from TV upstream drains and check for iron
presence
Demineralized Water
Demineralized water header is normally put out of service just by closing
isolation valve at BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action
1
In case of maintenance of the header itself, it is better to wash the system using
Utility Water (through temporary connections) from BL to the end of the header
(removing the FT orifice plate and blind flange at the end) in order to save Demi
Water wastage.
5.2.9
Action
1
Open first the warming up bypass valve to warm-up slowly the header (if required after
long shutdown period). Keep it open for at least 2 hours
Slowly open BL valve and gradually warm up the system by draining condensate from low
points such as drains and hose connections
When condensate is clean and hot enough, close drain valves and check header steam traps
performance
Fully open BL valve and pressurize the system (check pressure via 33-PG-404)
In case of maintenance of the header itself, it is better to wash the system using
Utility Water, (through temporary connections) from BL to the end of the header
(removing FT orifice plate and the blind flange at the end) and then blow the
system with steam until everything is clean.
5.2.10
5.2.11
Crack open isolation valve at BL and pressurize the system (check pressure via 33-PG-403)
Close all user valves (line block valve upstream of each control valve)
Open first the 1 warming up bypass valve to warm-up slowly the header (if required after
long shutdown period). Keep it open for at least 2 hours
Slowly open BL valve and gradually warm up the system by draining condensate
When condensate is clean and hot enough, close drain valves and check header steam traps
performance
Fully open BL valve and pressurize the system (check pressure via PG-402)
In case of maintenance of the header itself it is better to wash the system with
utility water, (through temporary connections) from BL to the end of the header
(removing the FT orifice plate and blind flange at the end) and then blow the
system with steam until everything is clean.
5.2.12
Open first the 3/4 warming up bypass valve to warm-up slowly the header (if required after
long shutdown period). Keep it open for at least 2 hours
Slowly open BL valve and gradually warm up the system by draining condensate
When condensate is clean and hot enough, close drain valves and check header steam traps
performance
Fully open BL valve and pressurize the system (check pressure via PG-401)
In case of maintenance of the header itself it is better to wash the system with
utility water, (through temporary connections) from BL to the end of the header
(removing the FT orifice plate and blind flange at the end) and then blow the
system with steam until everything is clean.
5.2.13
5.2.14