2011 PLANT OPERATIONS MODULE 8 Maintain Bulk Plant Systems and Equipment

2011 PLANT OPERATIONS Module 8 – Maintain Bulk Plant Systems and Equipment Recognize and avoid hazards associated with inspecting and servicing bulk plant systems and equipment. Identify sources for guidelines on how to: –Assess the proper location, installation and operating condition of each piece of equipment. –Service or replace components where necessary and appropriate. –Verify that all systems comply with applicable codes and regulations. Find and follow written procedures for all bulk plant operations for which you are responsible. 2

2011 PLANT OPERATIONS LESSON 1 Observe Safety Precautions When Performing Maintenance Activities 3

LESSON PLANT OPERATIONS Lesson 1 – Observe Safety Precautions When Performing Maintenance Activities Avoid fire hazards. Avoid personal injury. 4

LESSON PLANT OPERATIONS Avoid Fire Hazards Remove ignition sources, flammable liquids and combustible materials to a safe distance. Be careful when disconnecting hoses or pipes. Electrical equipment should be serviced only by a qualified person. Be careful handling flammable liquids. 5

LESSON PLANT OPERATIONS Avoid Personal Injury Wear appropriate PPE. Be careful when climbing. Do not operate fork lift truck unless properly trained. 6

2011 PLANT OPERATIONS Lesson 2 Inspect and Maintain Bulk Plant Systems and Equipment 7

LESSON PLANT OPERATIONS Lesson 2 – Inspect and Maintain Bulk Plant Systems and Equipment Regular inspections. Accurate written records. 8

LESSON PLANT OPERATIONS Maintenance Procedures and Checklists 9

2011 PLANT OPERATIONS Lesson 3 Follow and Maintain Bulk Plant Procedures 10

LESSON PLANT OPERATIONS Lesson 3 – Follow and Maintain Bulk Plant Procedures Written procedures required. Employees must know. –Where to find them. –How to carry out responsibilities as specified. 11

LESSON PLANT OPERATIONS Required Procedures Operation of systems and equipment, including:  Normal startup, operation and shutdown.  Emergency shutdown and recovery including: –How to identify the problem. –How to safely resume operation.  Startup following a major change to the system, such as: –Addition or replacement of pumps, valves, electrical systems and such. –Changes that add or change steps in an operating procedure. –Changes that affect criteria for making decisions.  Consequences of deviations and steps required to correct or avoid deviations. –Deviations include failure to operate a system as intended, failure to follow a procedure step by step as written, and attempts to circumvent safety systems. –Consequences may include personal injury, damage to facilities or equipment, adverse environmental impact and economic loss. 12

LESSON PLANT OPERATIONS Required Procedures Inspection and maintenance of plant systems and equipment, including: –Frequency of inspections. –Criteria for continued service of the device (inspection checklists). –Record keeping. –Retention and use of maintenance manuals. Safety precautions and PPE requirements, including: –Fire prevention and inspection and maintenance of fire protection equipment. –Avoidance of personal injury. –Action required in the event of personal injury. 13

LESSON PLANT OPERATIONS Required Procedures Plant security and access control, including: –Those that limit access by non-employees –Those that satisfy requirements for security training as dictated by the Department of Homeland Security CFATS. Emergency action and evacuation. 14

LESSON PLANT OPERATIONS Summary Every bulk plant must: –Create and maintain written procedures for all operations. –Insure that procedures o Comply with all applicable codes and regulations. o Are updated when changes are made. –See that employees know where to find written procedures. Employees must know: –What to do. –When to do it. –How to do it safely. –Why it matters. –What to do if it doesn’t go as expected. 15

LESSON PLANT OPERATIONS Case Study – Written Instructions and Recordkeeping, Case #1 16

LESSON PLANT OPERATIONS Case Study – Written Instructions and Recordkeeping, Case #2 17

2011 PLANT OPERATIONS Module 8 Quiz 18