OGTS – P08 - Shut Down Operations PDF

Basic Oil and Gas Processing Operations Practice OGTS – P 08  17 July 2024 | 2 Acknowledgement This training material has been prepared by Dietsmann and UPIK-Operation lecturers covering OGTS-P08, Outcomes 01, 02 and 03 for...

Basic Oil and Gas Processing Operations Practice OGTS – P 08  17 July 2024 | 2 Acknowledgement This training material has been prepared by Dietsmann and UPIK-Operation lecturers covering OGTS-P08, Outcomes 01, 02 and 03 for the Tilenga Academy in accordance with OPITO curriculum and industry best practices.  24 June 2019 / ‹#› LEARNING OUTCOME Carry out start up operations for oil O1 and gas process plant/equipment Monitor and record plant/equipment O2 readings Carry out shut down operations for O3 oil and gas process plant/equipment  24 June 2019 / ‹#› SESSION OBJECTIVES P3.1 Shut down the oil and gas process in accordance with operating instructions/checklists P3.2 Restore the work area to a safe condition  5 Are process equipment shut down at the of the day? What do you understand by safe work place restorations?  6 P3.1 Shut down the oil and gas process in accordance with operating instructions/checklists  7 Shut down Operations  In industries that involve heavy equipment, safety is of utmost importance. Implementing proper shutdown and lockout/tagout procedures is crucial to ensuring the well-being of workers and preventing accidents.  Equipment shutdown means the process of taking a unit of equipment off- line from an operative condition such that normal production rates are not being achieved.  8 Shut down Procedures  Shutdown procedures involve the systematic process of shutting down equipment and ensuring that all operations have been safely terminated.  This includes turning off power sources, closing valves, and securing machinery.  9 Role of Shutdown Procedures 1. Allow workers to safely perform maintenance, repair, or cleaning tasks without the risk of unexpected energization or startup. 2. Enable the identification and correction of equipment malfunctions, reducing the likelihood of future accidents thus contributing to the overall efficiency and longevity of heavy equipment. 3. Provide an opportunity for workers to assess the overall condition of the equipment. They can inspect for any signs of wear and tear, leaks, etc.  10 Lockout/ Tag out Procedures  On the other hand, lockout/tagout procedures involve physically locking and tagging equipment to prevent it from being re-energized or operated accidentally.  Lockout devices, such as padlocks, are used to immobilize machinery, while tags indicate that it is unsafe to operate.  11 Lockout/ Tag out Procedures Cont’d  For instance, in the case of a large industrial press, lockout/tagout procedures involve isolating the machine from its power source, such as disconnecting it from the electrical grid or shutting off the main power supply.  12 Preparing for Shutdown  When pausing a manufacturing line, it is crucial to allow the machine to empty itself of all the components. The end of the production sequence clears the manufacturing equipment without loading new products into the cycle. This cycle finishes components in a machine and automatically removes most of the glue, parts, liquid, and powder from the production path.  For instance, during a temporary equipment shutdown where oil was left inside certain vessels. This oil froze and hardened during the production disruption. At the time of restarting the line, the oil had become like a resin, gumming up the machine and requiring cleaning that was more labor-intensive and time- consuming than if it was completed at the time of the shutdown.  13 Preparing for Shutdown Cont’d  Prior to initiating shutdown procedures, it is also crucial to conduct a thorough assessment of the equipment and its associated risks i.e. identifying potential hazards, such as stored energy sources (hydraulic systems or electrical circuits) or confined spaces, etc.  Additionally, clear communication is essential. Informing all personnel involved about the shutdown process, potential hazards, and necessary precautions ensures that everyone is on the same page and can work together safely.  14 The Shutdown Process: A Step-by-Step Guide 1. Notify all personnel involved about the impending shutdown. 2. Securely power down all equipment by following the manufacturer's guidelines/SOPs. 3. Close and secure all valves, switches, and controls. 4. Relieve any stored energy to eliminate potential hazards. Some equipment may store energy, such as pressure or electrical charge, even when powered down. This may involve releasing pressure from hydraulic systems, discharging capacitors, or safely grounding electrical circuits.  15 The Shutdown Process: A Step-by-Step Guide 5. Physically lock and tag equipment to prevent accidental operation.  16 P3.2 Restore the work area to a safe condition  17 Restore work area to safe conditions 1. On completion of an activity, you will need to be able to reinstate the work area correctly whilst adhering to Health and safety legislation, regulations and safe working practices. 2. Work safely at all times, complying with your organization's procedures. 3. Withdraw all possession and protection measures in line with your organization's procedures. 4. Confirm the work area is secured on completion of the work.  18 Restore work area to safe conditions Cont’d 5. Restore the work areas to a safe condition in accordance with agreed requirements and schedules. 6. Separate equipment, components, and materials for re-use from waste items. 7. Store reusable materials and equipment in an appropriate location. 8. Identify, mark and secure any waste items that cannot be removed immediately in such a way that the safe operation of the railway is maintained  19 Restore work area to safe conditions Cont’d 9. Check that all plant, tools, and test equipment that cannot be removed are secured and stored where they do not interfere with the safe operation of the railway. 10. Dispose of waste items in line with your organization's procedures. 11. Deal promptly and effectively with problems within your control and report those that cannot be resolved.  24 June 2019 / ‹#› 1. Is isolation of equipment from the power source, a LOTO procedure? 2. Why is it crucial to allow a machine empty itself of all the components before shutting down? 3. Lockout devices, such as padlocks, are used to …………………..., while tags indicate that ……………………………….. 4. Shutdown checklists are necessary. True/False