Safety Operating Procedures required in an LPG plant

https://anurageros.blogspot.in/2017/09/safety-operating-procedures-required-in.html

STANDARD OPERATING PROCEDURES : LEAK DETECTOR (VL/BL DETECTION)

1.       DRAIN OUT THE WATER FROM THE AIRLINE . BLOW OUT DIRT AND WATER FROM THE FILTER REGULATOR UNIT OF LD-01. CLEAN ALL THE PHOTO DIFFUSIVE SENSORS OF LD-01

2.       RESET LD-01 BY PRESSING THE (.) DOT BUTTON ON THE TOP RIGHT CORNER OF HMI AND WAIT TILL ‘CUC IN PROCESS MODE’ DISPLAYS. PRESS START BUTTON

3.       PUT VL TEST CYLINDER ON THE CONVEYOR.

4.       CHECK WHETHER THE UNIT IS REJECTING IT OR NOT. IF THE CYLINDER IS NOT GETTING REJECTED ADJUST THE SENSITIVITY SO THAT VL CYLINDERS OF LEAKAGE ABOVE 0.5GM/HR ARE REJECTED.

5.       CARRY OUT THE CHECK EVERY TWO HOURS AND RECORD IT.

STANDARD OPERATING PROCEDURES : LEAK DETECTOR (O RING LEAK DETECTION)

1.       DRAIN OUT THE WATER FROM THE AIRLINE . BLOW OUT DIRT AND WATER FROM THE FILTER REGULATOR UNIT OF LD-02. CLEAN ALL THE PHOTO DIFFUSIVE SENSORS OF LD-02

2.       RESET LD-02 BY PRESSING THE (.) DOT BUTTON ON THE TOP RIGHT CORNER OF HMI AND WAIT TILL ‘CUC IN PROCESS MODE’ DISPLAYS. PRESS START BUTTON

3.       PUT ORL TEST CYLINDER ON THE CONVEYOR.

4.       CHECK WHETHER THE UNIT IS REJECTING IT OR NOT. IF THE CYLINDER IS NOT GETTING REJECTED ADJUST THE SENSITIVITY.

5.       CARRY OUT THE CHECK EVERY TWO HOURS AND RECORD IT.
STANDARD OPERATING PROCEDURES : VALVE CHANGE WITHOUT EVACUATION

STEP1:SWITCH ON THE HYDRAULIC POWER PACK

STEP2:LOADING

1.       INTRODUCE THE LPG CYLINDER ON THE BASE PAD (RUBBER PAD) OF THE MACHINE AND CENTER IT APPROXIMATELY UNDER THE SEALING BELL.

2.       IN THE START OF OPERATION, SEALING BELL & TOLL REMAIN IN ITS UPWARD POSITION.

3.       OPERAT THE (WRENCH SHAFT LEVER) HAND VALVE DOWN POSITION FOR LOWER WRENCH SHAFT.

4.       THE WRENCH SHAFT LOWER DOWN & ENTER IN SEALING BELL, WRENCH SHAFT HOLD NEAR THE BALL VALVE, UNTIL BALL VALVE FULL OPEN (A PNEUMATIC ROLLER VALVE MOUNT AT SEALING BELL STRUCTURE, THIS ROLLER VALVE PRESSED BY ALUMINIUM SLID FIX ON THE WRENCH SHAFT STRUCTURE PORTION & MOVE UP & DOWN WITH WRENCH SHAFT & GIVE THE SIGNAL TO THE BALL VALVE ACTUATER FOR BALL VALVE OPEN/CLOSE)

5.       AFTER OPENING THE BALL VALVE, WRENCH SHAFT ENTERS IN THE BALL VALVE & CLOSE IT OR SEALING BELL LEVER.

6.       OPERATE THE (SEALING BALL LEVER) HAND LEVER VALVE DOWN POSITION FOR DOWN THE SEALING BELL.

7.       LOWER THE SEALING BELL UNTIL THE WRENCH IS SLIGHTLY ABOVE THE TOP OF THE CYLINDER VALVE (WRENCH SHAFT ARRANGEMENT DOWN WITH SEALING BELL BECAUSE WRENCH SHAFT ARRANGEMENT ATTACHED WITH BELL PORTION).

               STEP 3: ALIGNMENT

1.       THIS STEP IS CRITICAL TO THE SUCCESS OF ALL FURTHER OPERATIONS

2.       SHIFT THE CYLINDER UNTIL THE CYLINDER VALVE IS ALLIGNED WITH THE WRENCH SOCKET.

3.       DO NOT TILT CYLINDER TO GET THIS ALLIGNMENT.

4.       THE FOOT RING OF THE CYLINDER MUST BE FULLY ON THE BASE PAD BEFORE ENGAGEMNT IS ATTEMPTED.

5.       USE THE VP RING OR BODY OF THE CYLINDER TO MOVE IT.

6.       DO NOT INTRODUCE YOUR HAND UNDER THE SEALING BELL.

7.       LOOK FROM TWO ORTHOGONAL POSITIONS TO ENSURE PROPER AXIAL ALLIGNMENT.

8.       LOWER THE SEALING BELL FURTHER SO THAT THE SOCKET ENGAGES THE VALVE.

9.       LOWER THE SEALING BELL FURTHER STILL UNTIL THE FACE CONTACTS, THE LPG CYLINDER & PRESSES DOWN FIRMLY ON IT.

10.   LEAVE THE SEALING BELL CONTROL LEVER.

11.   YOU ARE NOW READY TO UNSCREW THE CYLINDER VALVE.

STEP4:UNSCREWING     

1.       SHIFT THE UNSCREW CONTROL LEVER AND HOLD IT UP TO ROTATE THE WRENCH ANTICLOCKWISE.

2.       AS THE VALVE UNSCREWS THE WRENCH SHAFT WILL CREEP UP AUTOMATICALY.

3.        WHEN THE VALVE IS FULLY UNSCREWED .THE WRENCH SHAFT WILL STOP CREEPING UP.

4.       KEEP THE UNSCREWING MOTION ON AND SIMULTANEOUSLY SHIFT THE WRENCH SLIDE LEVEL TO THE UP POSITION.

5.       AS SOON AS THE WRENCH LIFTS 40 TO 50 MM RELESE THE UNSCREW CONTROL LEVELBUT KEEP WRENCH TOOL VALVE IN THE UP POSITION TO CONTINUE LIFTING THE SHAFT.

6.       LPG PRESSRE RISE IN THE PRESSURE GAUGE. PRESSURE GAUGE MOUNTS ON THE SEAL BELL

7.       WHEN THE WRENCH SHAFT WITH SC VALVE CROSSED THE BALL VALVE 20MM (AFTER LIFTING 320 MM FROM SEALING BELL LOWER PORTION), A PNEUMATIC ROLLER LEVER VALVE GIVES THE SIGNAL TO BALL VALVE FOR CLOSING.WRENCH SHAFT WILL LIFT OUT OF THE SEALING BELL WITH THE VALVE ALLOW IT TO TRAVEL FULLY UP.

STEP5: SCREWING

1.       AFTER REPLACING THE NEW SC VALVE ON THE WRENCH SOCKET, PRESS WRENCH LEVER DOWN POSITION TO MOVE THE WRENCH SHAFT IT’S DOWN POSITION.

2.       THE WRENCH SHAFT ENTER IN THE SEALING AREA & STOP NEAR THE BALL VALVE (A PNEUMATIC ROLER GIVE THE SIGNAL FOR OPEN THE BALL VALVE).

3.       AFTER FULLY OPEN THE BALL VALVE WRENCH SHAFT MOVE DOWN POSITION.

4.       NOW SHIFT THE SCREW LEVER FOR SCREWINING TO ROTATE THE WRENCH SHAFTCLOCKWISE.

5.       THE WRENCH SHAFT DOWN MOVE SLIGHTLY. AFTER VALVE SCREWING THE WRENCH SHAFT WILL STOP AUTOMATICALY.

6.       YOU HAVE NOW SCREWED THE NEW VALVE ON CYLINDER.

7.       NOW RELEASE THE SCREW LEVER STOP POSITION & SHIFT THE SEALING BELL LEVER IT’S UP POSITION.

8.       NOW PRIMARY VENT IS ON FOR LPG PRESSURE VENTILATION IN COLD FLAIR.

9.       AFTER COMPLETE THE LPG FLAIR.SEALING BELL LIFT UPPER SIDE.

10.   BELL WILL NOT LIFT UP IF THE PRESSURE INSIDE THE BELL IS NOT 0 TO 0.5GM FOR THIS SAFETY INTERLOCK, TWO PNEUMATIC PRESSURE SWITCHES CONNECTED WITH SEALING BELL. WHEN IT GIVES THE SIGNAL FOR COMPLETE FLARING SEALING BELL WILL LIFT OTHERWISE IT WILL NOT LIFT UP.

STEP6: SHUT DOWN PROCEDURE END OF THE DAY SHIFT.

1.       THE END OF THE DAY THE MACHIN SHOULD BE SHUT DOWN IN THE IN THE CORRECT CONDITION.

2.       THERE SHOULD BE NO CYLINDERS IN THE MACHINE.

3.       MOVE THE SEALING BELL DOWN TO ITS LOWEST POSITION AND LEAVE THE CONTROL LEVEL IN NATURAL.

4.       MOVE THE WRENCH SLIDE DOWN TO ITS LOWEST POSITION AND LEAVE THE CONTROL LEVER IN THE SHUTDOWN POSITION.

5.       SWITCH OFF THE HYDRAULIC POWER PACK.

6.       TURN OFF THE AIR SUPPLY

               NOTE: PROBLEMS DURING SCREWING/UNSCREWING

1.       IN THE CASE VALVE NOT COMPLETE THE SCREW/UNSCREW, VALVE DROP OUT THE WRENCH IN THE SEALING BELL AREA.

2.       IN SUCH CASE THE LPG IN THE CYLINDER MUST BE VENTED VIA SECONDARY VENT BEFORE THE SEALING BELL CAN BE LIFTED.

3.       A LPG VENTILATION PIPELINE ATTACHED WITH PRIMARY & AND SECONDARY VENT LINE FOR REMOVING THE LPG PRESSURE FOR COLD FLAIR

               INTERLOCKS:

1.       AN INTERLOCK PROVIDED FOR CHECKING THE BALL VALVE CLOSED POSITION, THE TOLL SHAFT UPWARD POSITION STOP IN SEALING AREA TILL THE BALL VALVE FULLY CLOSED SIGNAL.

2.       AN INTERLOCK PROVIDED FOR CHECKING THE BALL VALVE OPEN POSITION THE WRENCH SHAFT DOWNWARD POSITION STOP IN SEALING AREA TILL THE BALL VALVE FULLY OPEN SIGNAL.

3.       THE PRESSURE SWITCH USED IN BELL. THE SEALING BELL LIFT UP,WHEN SEALING BELL INSIDE PRESSURE IS NILL.

4.       A PRESSURE RELEASE VALVE PROVIDED IN POWER PACK FOR AVOIDING THE OVER PRESSURE.THIS VALVE RELESE THE EXTRA OIL PRESSURE IN RETURN LINE.

 STANDARD OPERATING PROCEDURES : AUTOMATIC VALVE TESTING SYSTEM (ELECTRONIC TYPE)

1.       NORMALLY WHEN THE MACHINE IS ON AND THERE IS NO TESTING GOING ON, THEN ‘INSPECTION OFF’  WILL  APPEAR ON THE GLASS WINDOW SCREEN.

2.       WHEN A CYLINDER COMES FOR TESTING AND DURING TESTING ‘INSPECTION ON’ WILL APPEAR ON THE GLASS WINDOW SCREEN.

3.       ONCE THE TESTING IS COMPLETED AND THE CYLINDER IS OK THEN ‘OK’ WILL APPEAR ON THE GLASS WINDOW SCREEN.

4.       DURING TESTING IF THE CYLINDER IS REJECTED FOR PIN LEAK OR ‘O’ RING DEFECT THEN ‘REJECTS’ WILL APPEAR ON THE GLASS WINDOW SCREEN.

DO’S AND DON’T’S

1.       DO NOT CHANGE THE POSITION OF SENSORS.

2.       DO NOT CHANGE THE AIR PRESSURE FROM THE MAIN FRL UNIT WHICH IS SET NORMALLY AT 5KG/CM^2.

3.       DO NOT CHANGE THE PRESSURE SETTING OF THE PRESSURE REGULATOR PROVIDED INSIDE THE CONTROL PANEL.

4.       DO NOT START THE MACHINE WITHOUT AS MUCH AIR AS IT MAY DAMAGE THE COMPONENTS.

5.       DO NOT ALLOW CYLINDERS TO MOVE ON BELLY FOR TESTING.

6.       DO NOT OPERATE FUNCTION KEYS DURING TESTING. (F1, F2, F3…)

7.       ALWAYS KEEP THE INLET AIR PRESSURE TO THE SYSTEM TO THE CORRECT VALUE.

8.       ALWAYS SUPPLY 230V AC TO THE MACHINE THROUGH UPS.

9.       CHECK FOR ANY AIR LEAKAGE IN THE SYSTEM, IF FOUND INFORM OFFICER IN CHARGE.

10.   WITH THE POWER ON DO NOT OPEN THE FLAME PROOF JUNCTION BOX OR TERMINAL JUNCTION BOXES PROVIDED AT THE BACK OF THE CONTROL PANEL.

11.   WITH THE POWER ON DO NOT TAMPER ANY ELECTRICAL CONNECTION.

FUNCTION PUSH BUTTONS IN THE CONTROL PANEL

THESE PUSH BUTTONS ARE TO BE OPERATED ONLY WHEN THE MACHINE IS NOT IN RUNNING CONDITION

F1 WHEN PRESSED WILL SHOW THE NUMBER OF CYLINDERS TESTED IN THE MACHINE

F2 WHEN PRESSED WILL SHOW THE TEST TIME

F3 WHEN PRESSED WILL SHOW SELECT PR ( TO SELECT THE TEST ACCURACY OF THE MACHINE VIZ 0.5,0.75,1.0)

F4 WHEN  PRESSED WILL SHOW PREVIOUS CYLINDER TESTED LEAKAGE VALUE IN TERMS OF CURRENT

UP TO BE OPERATED ONLY TO INCREASE THE F2 BUTTON VALUE OR F3 BUTTON VALUE

DOWN TO BE OPERATED ONLY TO DECREASE THE F2 BUTTON VALUE OR F3 BUTTON VALUE

RESET WHEN PRESSED WILL ERASE THE F1 VALUE

M-RESET TO BE OPERATED ONLY WHEN THE  SUPPLY AIR PRESSURE FALLS BELOW THE SET VALUE AND ‘PNEUMATIC LOW’ APPEARS ON HMI