Document 6YoJ7L9ZROd80y4wLKE60DEd

Sdf,-? /V WRITTEN BY: "PULLEM" OAT APPROVED BY: DERIVATIVE'S AREA SUPERVISORS DATE: 6/22/88 t CHECK 1 1 1 ACTION STEPS (Capital "" -- letters) wi i ..........a and Comments n- (Small letters) | I This SOP is written to develop a uniform procedure throughout Derivatives to ensure that the appropriate steps are taken prior to removing from service or bypassing an alarm, instrument, or shut down system automatic valve. This SOP will provide an effective way of communicating the status.of these instruments to others and making sure that the necessary steps are taken to correct the problem. This procedure is intended to apply to all pressure, temperature flow, level, analyzer, etc. instrumentation and the associated control valves. This SOP is considered to be each unit's minimum standard. Each unit reserves the right to require a higher level cf reliability if it is deemed necessary by the unit supervision. 1. IF AN ALARM, INSTRUMENT, OR SHUT DOWN SYSTEM MALFUNCTIONS, THI OPERATOR'S FIRST RESPONSE SHOULD BE AN ATTEMPT TO FIX IT. O) In every circumstance, the first response should be a LO reasonable effort toward correcting the cause of the LO O problem. Operating without alarms, instrumentation, or shu down system valves introduces a level of ri3k that is not O desirable. 2. CHECK TO MAKE CERTAIN WHAT PRIORITY THE ALARM OR CO INSTRUMENTATION FALLS INTO: 4J k, u3 0 *Mc u -uw * > u .3 aj a* <. 1' K * *< o --< z *> t u o --< ^ O U C O' >"1 t, --I Cu u X O -h c* O t: X U 4J 3 o T*l 4J JO *.= -4 v> <*> O. Check the list of alarms attached m the unit SOP manual to determine what the priority of the alarm is. The priority system to be used is as follows: Priority - Critical instruments whose failure would eithe: cause or fail to inform of situations causing accidental fire, explosion, uncontrolled release of dangerous materials, reportable environmental releases, or, major property or production loss. These alarms include those which have been mandated by outside agencies (RCRA, EPA, DEQ, Consent Decree), also Operations Review Committee (ORC) reliability alarms, and alarms deemed critical by operations supervision. All of these alarms are on the prooftesting schedule. Priority 2. - Critical instruments whose failure could eithe: cause or fail to inform of serious conditions involving recordable environmental releases, property or productio: losses, or other non-life threatening situations. These are slightly lower priority alarms which are also on the prooftesting schedule. Priority 3_ - All other alarms, which are not on the prooftesting schedule. S'-2. Note: Op ra-tions will treat priority 1 and 2 alarms m an identical fashion. The only reason that these are differ ntiated is for th sake of the prooftesting program^' " " ^ IF THE ALARM IS PRIORITY 1 OR 2, GO TO STEP S. IF THE ALARM IS PRIORITY 3, GO TO STEP #3. 3. RESPONSE TO' PRIORITY 3 ALARMS. THE LEAD OPERATOR SHOULD FOLLOW ESTABLISHED UNIT PROCEDURES AND HIS KNOWLEDGE OF THE UNIT TO EVALUATE EACH SITUATION AND MAKE A DECISION AS TO WHETHER THE INSTR, U, ME' NT. CAN BE BYPASSED OR NOT. If there is 'an!y Edoufc>t about, this choice, supervision should be consulted. These alarms and instrumentation are not considered ci under normal conditions. THE LEAD OPERATOR SHOULD IMPLEMENT THE OUT-OF-SERVICE PROCEDURE FOR PR,IfOc .;RISTOY1' V3- ALARMS. This will include taking immediate action to initiate repairs. This means that at least a note m the maintenanc logbook must be made to initiate repairs to orevent the problem from being forgotten. STOP HERE FOR PRIORITY 3 ALARMS. RESPONSE TO PRIORITY 1 OR ALARMS. RCRA, EPA, CONSENT DECREE, OR CRITICAL ALARMS, INSTRUMENTATION OR SHUT DOWN HSYSTEM AUTOMATIC VALVES. NOTIFY YOUR LEAD OPERATOR OF THE SITUATION. No one except the unit lead operator or supervisor has the CO authority to approve taking an alarm out of service. 6. THE LEAD OPERATOR WILL DECIDE IF IT IS SAFE TO TAKE THE INSTRUMENT OUT OF SERVICE. IF IT IS SAFE TO DO SO, THE LEAD OPERATOR WILL COMPLETE AN "OUT-OF-SERVICE" TAG AND MOUNT IT 0 THE CONTROL PANEL. HE WILL ALSO MAKE NOTE IN THE OPERATIONS LOGBOOK TO EXPLAIN THE DETAILS OF WHAT HAS BEEN DONE AND WHY IT WAS NECESSARY. IF, IN THE LEAD OPERATOR'S OPINION, IT IS NOT SAFE TO DO SO, SUPERVISION SHOULD BE CONSULTED. k The out-of-service tag i3 intended to be a communications tool for notifying other people that Priority 1 fcor 2 alarms are out of service. These tags should be affixed to the instrument on the control panel or, if this is' non ^possible in another prominent place on the control panelI 1 These out of-service tags will remain on the board until the -situatio 13 corrected. 7r 1 There are circumstances during routine operatwhen some of these alarms or valves need to be taken out' of s rvi( for short periods of time to perform short term'routine on the system. Some examples of this include tfre following ci). Pulling alarm cards at EDC I to look for':-a; "mystery alarm". (2). Taking alarms out of service on th computer at VCM II long enough to identify them on the CRT display. -^6'- / ? / -> (3). When an operator and log book instrument man go outside to look at., a shut down system valve that is sticking. t" (4). When OHC analyzers are bypassed for preventive maintenance work. Under these and other similar circumstances it would not normally be worth l;he.effort to complete an out-of-service tag. For these short-term situations it will be acceptable practice for the alarm* .instrument, or control valve to be taken out of service provided that both of the following criteria are metT' 1) The lead operator is informed of the situation and gives approval. 2) The operator .g.ity,es undivided attention to this problem. If both of thesd cahjOAt .^be met, then the out-of-service tag must be used regarH^fess of the length of time required for the work to be done. The out-of-service* rt-a) gs are not a substitute for performing maintenance. Th_e oqp-of-service tags 3erve only to communicate the'Status of instruments m need of repair. 8. TAKE IMMEDIATE ACTION TO INITIATE REPAIRS ON THE OUT-OF SERVICE INSTRUMENT. Ub in o 0) After a priority 1 or 2 alarm, instrument, or control valve has been properly taken out-of-service or bypassed, it should not be forgotten about. On day shift this may requir redirecting the maintenance logbook priorities, or notifyin supervision so an "Emergency" work order can be written. 0 the back shifts and during holidays, this may mean notifyin the shift supervisor and getting shift mechanics or calling out mechanics so that the repairs can be made m a timely fashion. In either case it is strongly recommended that repairs be started as soon as practical. Ordering "nut-of-Service" tags. These tags are set up in our reproduction department with a form number (5$A-6) so that day shift operators can reorder these by tel phone. w tn-- 9. >)) - tw: O .w. >o --L. H -H Ji < 4* K * *-- p ~vm` .10. XH S) C -it i3 0 s a. --i Cl. U o 4J *r z oo a t-a o O * W WHEN THE REPAIRS ARE SUCCESSFULLY COMPLETED AND THE ALARM, INSTRUMENT;' OR CONTROL VALVE IS PUT BACK INTO SERVICE* THE LEAD OPERATOR WILL REMOVE THE OUT-OF-SERVICE TAG FiJQM'JI&E BOARD, TAPE IT INTO THE LOGBOOK, AND COMPLETE THE BOTTOfc SECTION OF THE OUT-OF-SERVICE TAG. 1-4 {- * A "WEEKLY OUT-OF-SERVICE TAGGING CHECKLIST" WILL BE COMPLETE BY EACH UNIT ON MONDAY MORNING GRAVEYARD SHIFT TO C0NFil$i THAT THE PANEL ALARMS AND LIGHTS ARE IN WORKING ORDE% AND THAT ALL OF THE OUT-OF-SERVICE ALARMS, INSTRUMENTATION^ AND CONTROL VALVES HAVE BEEN PROPERLY TAGGED ACCORDING TQ ^HIS SOP. THESE CHECKLISTS WILL BE MAILED TO THE DERIVATIVES ENVIRONMENTAL FOREMAN EACH WEEK FOR RECORDKEEPING AND.t AUDITING. The objective of the weekly checklist i3 to routinely take an inventory of the out-of-service tagging which has been done and to correct all tagging deficiencies on the spot. sps (7 S-y Each individual unit will make up a detailed checklist whic will b fltitl d "W #kly Out-of-Servic Tagging Checklist*. During this we kly inventory, the audible and visual should be proven to be in working order. A check of a^P f* the out-of-service tags on the panel will be made to insure that they all have been done correctly. Also a cross-check in the field will be made to insure that no bypassed SDS automatic valve has been overlooked. All tagging discrepancies which are found should be corrected on the spot by following 3tep #11 below. 11. IF A PROBLEM IS IDENTIFIED DURING THE WEEKLY CHECKLIST WHICH HAS NOT BEEN PROPERLY "OUT-OF-SERVICE" TAGGED. THE DEFICIENCY MUST BE CORRECTED IMMEDIATELY. RETURN TO STEP #1 ABOVE AND FOLLOW THIS SOP TO INSURE THAT EACH ITEM IS PROPERLY OUT-OF-SERVICE TAGGED. 12. THESE CHECKLISTS WILL BE REVIEWED BY THE UNIT SUPERVISORS AN: AREA SUPERVISOR, INITIALLED, AND MAILED WEEKLY TO THE DERIVATIVES ENVIRONMENTAL FOREMAN. CONPiDENTI^> Subject V' "" biltrlct Court ' nth judicial u & V*