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Plant Operation 1

Unit 3 : Documents Used for Operation of Process Plants

INTRODUCTION


Communication can be verbal or written form All the communication need to be clear and recorded It is for checking of production and maintenance history of the production plants
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PROCESS DIAGRAM


To understand the operation and layout of process plant System Diagrams :  Block diagrams  Piping diagrams  Flow diagrams  P&IDs
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BLOCK DIAGRAM (PROCESS FLOW CHART)


 

Block and Arrow to represent equipment and process flow To describe a process system

FLOW DIAGRAM
 

Symbols to represent equipment (tanks, pumps, etc) Does not show devices used to monitor the process

PIPING & INSTRUMENTATION DIAGRAM (P&ID)




Includes instruments such as Flow Indicator (FI), Level Indicator (LI)

TYPES OF DOCUMENTATION
Process Diagrams Daily Operating Instructions (DOI) Operator Log Book Product Specification Record Unit Technical Manual Safety Manual Material Safety Data Sheets (MSDS) Daily Operation Record

TYPES OF DOCUMENTATION
Standard Operating Work Requests Conditions (SOCs) Operating Procedures Standard Operating Manual Procedures Work Permits

DAILY OPERATING INSTRUCTIONS (DOI)


 

Located in the control room Include information that technicians need to know about product scheduling, daily operating

objectives or targets, special operating instructions, maintenance schedules, etc




Also known as daily order book


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LOGBOOK


To

record

significant

events

or

unusual

occurrence to pass on to next shifts technicians and supervisors




Should be kept accurate and short (date, time, equipment no., badge no., etc)

Record:

Safety hazards Equipment problems

Operational problems Operational adjustments


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PRODUCT SPECIFICATION SHEETS




Provides information about the products produced by the unit

List the properties used to judge product quality and the acceptable values for on-specification product

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STANDARD OPERATING CONDITIONS (SOCs)




Goals and acceptable ranges for the process variables such as temperature, pressure, flow. level, composition)

Operating within these ranges is necessary to produce on-specification product


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OPERATING PROCEDURES MANUAL




Contains

detailed

instructions

for

proper

operation of the process unit.




Include

startup,

shutdown,

and

emergency

procedures, plus normal operating procedures.




May also include safety information

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UNIT TECHNICAL MANUAL




Contains detailed information about the unit process and equipment such as:


Process description, the process chemistry, unit limitations, information about major equipment

(construction material, stress rating, dimensions, etc.)

Summary of the unit's instrument control strategy


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SAFETY MANUAL


Contains detailed information about unit safety procedures, site safety policies, and safety standard operating procedures (SOPS).

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MATERIAL SAFETY DATA SHEETS (MSDS)




Provided by the suppliers of the chemicals

Provide data on toxic, flammable, and reactive characteristics of the chemical

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MATERIAL SAFETY DATA SHEETS (MSDS)




Also a source of information on safety equipment that should be used and special precautions that should be followed when handling these

materials.

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DAILY OPERATION RECORDS




Generated by technicians during their working shift.

Historical records that can prove useful when troubleshooting and updating procedures.

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WORK REQUESTS


Used to request service and repair of process equipment.

Also provides a record of the completed maintenance work on each unit

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STANDARD OPERATING PROCEDURES (SOPS)




A set of steps to follow for


   

Normal operations starting-up shutting-down Emergency situations

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LABORATORY ANALYSIS REPORT




Gives standard specifications and benchmarks for products

Used

to

communicate

between

laboratory

technicians and operators

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SAMPLE INFORMATION


Information gathered by sample from laboratory

Used to plan production rate

Test Result
 

Sometimes conducted by operators Recorded as part of laboratory report


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TEST RESULT


Sometimes conducted by operators

Recorded as part of laboratory report

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PERMIT TO WORK SYSTEM (WORK PERMIT)




A special document (permit) before certain types of work can be done. A formal written system used to control certain types of work which are identified as potential hazardous.

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PERMIT TO WORK SYSTEM (WORK PERMIT)




Ensure personnel involved in a hazardous task to take the time to review all the steps, personal protective equipment (FPE), hazards, and additional equipment required to perform the task safely. A means of communication between site/installation, maintenance personnel and contractors to ensure all necessary safety precautions are taken before commencing the work.

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PERMIT TO WORK SYSTEM (WORK PERMIT)


Some of the more common permits are  Confined spaces  Lockout/tagout (LOTO)  Hot work  Cold work There are three permit systems very  Opening/ blindimg common to the petrochemical and refining industries because OSHA mandates them:  Radiation (1) Hot work  Critical lifts (2) Lockout/ Tagout (3) Confined space.  Electrical
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HOT WORK PERMIT




Any maintenance procedure that produces a spark, excessive heal, or requires welding or burning. The permit must be displayed at the worksite until the hot work operation is complete.

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LOCKOUT/ TAGOUT PERMIT




In a lockout system, a padlock is placed to prevent energy from being turned on. A tagout system is just like a lockout system except a tag is included with the lock if the equipment can accept a lock.

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VESSEL ENTRY PERMIT/ CONFINED SPACE ENTRY PERMIT




A confined space may contain a toxic atmosphere, chemicals, an oxygen deficient atmosphere, flammable materials, power-driven equipment, or other hazardous conditions Need a permit to enter

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VESSEL ENTRY PERMIT/ CONFINED SPACE ENTRY PERMIT




Some examples are:  Storage tanks  Large pipes  Silos  Distillation towers  Underground cable ducts

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