Document XRRe3vOrmvdnpDVJqapXYOVJ4

CONFIDENTIAL; Subject to Protective Order of 14th Judicial District Court No. 91-1145 PER TRI REACTORS TOTAL OUTAGE PROCEDURE DATE: // WORK ORDER NO. INSTRUCTIONS: This form is to be returned to Per-Tri reactor foreman after all the jobs have been completed. The form itself is a reminder and a guideline for the foreman/mechanic, and operators. It is also a record for operations. Please indicate the date when the job was completed on the blank provided. Because there v. i 1 1 be ~interai. s < ... butncmi main tenance and operations, the foreman following the jobs or the lead operator is to sign and date the form prior to returning it to the other. This form is to be attached to the REACTOR ISOLATION AND TAGGING CHECKLIST and to the RXSOP112 but will become independent after the outage begins. At the end of the packet you will find a blank form. This form is to record information relevant to the outage, ie. IF OPERATIONS BECOMES AWARE THAT A VALVE NEEDS TO BE REPLACED OR THAT A NOZZLE NEEDS TO BE UNPLUGED. this information is to be written on this form immediately. MATERIAL NEEDED 1. Operating air compressor with full fuel tank 2. Two operating fork trucks with full fuel tank 3. 45 drums with lids and rings 4. Roll of visqueen 5. Two low voltage light cords and two spare bulbs 6. Low voltage transformer and extension cord 7. Fre hose and tank washer 8. 1u blue drums with lids and rings PREPARAT jNS (Must be completed prior to the schedule outage date) _____ 1. _____ 2. _____ 3. ______ _____ _____ _____ _____ 4. 5. E. 7. 8. ______ 9. _____ 10. _____ 11. Park air compressor away from scrubber area Clear area where vacuum truck will be parked (it must be within contained area) Locate pallets/drums/1ids on road south of reactors Identify the drums as "USED CATALYST" "NO.__ PER TRI REACTOR" Loanee: ana i . . * ullage lights Build scaffolds to remove heads Review procedures with mechanics Clear blasting area Build platform to unbolt organics to vaporizer from main header Build platform to remove dowtherm SRV Move reactor head racks South of reactor's area Schedule instrument mechanics and insulators to disconnect thermocouples and remove heads/piping insu1 a tion SI 2l227 TAGGING (To be done the morning the outage starts) _____ 1. _____ 2. _____ 3. Complete REACTOR ISOLATION AND TAGGING CHECKLIST Hang checklist and reactor number tag on I-Beam West of stairway according to LOCK AND TAG procedure Maintenance and operations to update tagging check list daily PREPARATIONS TO REMOVE CATALYST USING VACUUM TRUCK _____ 1. _____ 2. _____ 3. _____ 4. Remove rupture di sks/sta-cks Remove reactor vapor line (includes the line from cyclone to primary condenser(s) Set lines by the blasting wall in a way that the blasters would be able to clean all sections. Remove pancake blind and sacrificial spools. Leave room for Rxheads. Cover grating hole by cyclone inlet Install pulley to hold dumping hose mtial hoses so that vacuum truck hoses could be.- connected to such hoses DATE: ___ / TIME: / FOREMAN: NOTIFY REACTOR FOREMAN SO THAT VACUUM TRUCK COMPANY COULD BE NOTIFIED. PREPARATIONS TO HYDROBLAST SYSTEM REACTOR 1. Remove feed piping and heads OL Disconnect nitrogen tubing to individuals and rod- out each tube (to be done simultaneously with item #1 ) 3. 4. 5. 6. dome thermowells catalyst addition pot (including valves) blind from charging nozzle bayonets and cover condensate nozzles black o prevent plugging. Remove drain piping (21,T. seshoe COWMS; _ .at-*** 7. mxin* tee cnbiect to vro*nistE 1. _ 2. _ 3. _ 4. ,, 5. _ 6. Remove vaporizer reboiler Remove pad-out header valves/blinds/plugs so that blasters can clean every section of piping. Also, remove pump bowl cover Remove vaporizer drum manway, float chambers Roll out blowdown (automatic) valve Remove demister drum Remove rupture disks and SRVs (Follow SOP for D/T) PAGE 2 OF 8 ; 021218 7. Remove vaporizer drum LCV and roll out bypass valve 8. Remove organics orifice plate (disconnect impulse lines and cap ahem i v <*aiei out of this system). Drop spool on #1 vaporizer from orifice to organic headers. On the others, drop small spool at the headers so that blasters can clean the piping 9. Break flanges apart on organic inlet to drum 10. Remove valve between cyclone and catch pot 11. Remove catch pot drain line at the pot NOTE: When these jobs are marked as done and the foreman returns this form signed, it will be an indication that no tags are in place that could prevent the blasting of any piece of equipment/piping within the reactor or vaporizer system. DATE: TIME: // FOREMAN: NOTIFY THE PLANNER SO THAT HYDROBLASTING TRUCK COMPANY CAN DO THEIR JOB BLASTERS TO CLEAN SYSTEM PER LIST IN CONTROL ROOM WASH FEED PIPING The return of this list to the maintenance foreman will signal that the blasting job was done to satisfaction unless specific instructions were given to him (use last page) DATE: ____ i TIME: _____ REACTOR FOREMAN: ESPECIAL NOTES WRITTEN: YES NO _____ 1. _____ 2. Install flange with hose connector to mixed feed header Install bayonets or blinds NOTE: When these jobs are done and the maintenance foreman returns this form signed, it will be an indication in,., w._. tags are in place that could delay the washing and nitrogen checking by operations that evening or as indicated at that time. See RXSOP112 (attached) for details. DATE: TIME: t/ FOREMAN: NOTIFY REACTOR FOREMAN SO THAT OPERATORS COULD BE INSTRUCTED ON WHAT TO DO AND WHEN _____ 3. _____ 4. Operators to wash feed nit rogen per SOP Recorded findings from list at the end of the piping and check individual the operation above on the packet SL 021219 t> \ r.r o nr NOTE: When the washing and checking is completed and this form is signed, it will indicate that any problems found with this system has been properly documented in the operations logbook and that any valves needing replacement has been properly identified outside with a tag. Any findings that requires maintenance action (such as rodding out individuals, changing tubings, etc) are also identified with a notice tag. DATE: TIME: // LEAD OPERATOR: PREPARATIONS TO WASH PRIMARY CONDENSERS 1. 2. _____ O. _____ 4. _____ 5. _____ 6. _____ 7. _____ 8. Roll out piping below primary and secondary condensers Remove primary condenser(s) inlet spool and install 144 * .... Remove tee bypass and install blinds Connect washing hose (water inlet, use fire hydrant East of refrigeration unit) and drain hose to collection pan. The hose connector should be equipped with a nitrogen fitting. Wash condenser(s) Check with operations prior to using any water if done b.v maintenance. Remove tee from top of condenser(s) for inspection Notify maintenance coordinator that the system is ready for an overall inspection (piping and bolts integrity, plugging, etc.) Maintenance will be informed of any action required after the inspection Open barometric condenser and break drain piping flanges for inspection VOTE: When these jobs are done and the maintenance foreman signs off this list, it indicates the condenser(s) have been properly prepared for washing by operations if the washing was to be done on back shifts or that the condenser(s) is/are ready for operations approval. DATE: // FOREMAN: NOTE: Checking the condition of the primary condenser(s) piping is an integral part of the routine inspection for this system. When the RX foreman signs this form it indicates the acceptance of the condenser(s) wash job and signals___ maintenanceWl ft I Ift f Alft ft ft rv tthU an t4 4thken jobInlv can_ conAti`nu..e... REACTOR FOREMAN: ASSEMBLING REACTOR _____ 1_____ 2. Verify that the hydroblasting list has been fully completed and accepted (signed) Verify that all repairs required during inspection paor j nr p SL 021220 _____ 3. _____ 4. _____ 5. ective Order district Court -1145 were completed to satisfaction Verify that all the individual nitrogen connections/ piping has been rod-out. Vei i f y that all instrument work on the oxygen rota meters have been completed Verify* that primary condenser(s) tee(s) are clean and satisfactory NOTE: Both maintenance and operations agreement is required prior to assembling the system DATE: // FOREMAN RXS' FOREMAN _ 6. _ 7. _ 8. _ 9. _ 10. _ 11. _ 13. _ 13, _ 14. ,, 15. Install reactor rupture disk stacks after being repaired per SOP Install reactor heads and feed piping a f t e r f 1 cn checking each nozzle Close up vaporizer drum and blowdown piping; (pump bowl must be clean and dry) Install vaporizer reboiler Install mixing tee, bayonets, and drain piping on horse-shoe Install vapor lines (Primary inlet spools must be i/icd ai good bj dye check) Button up primarv condenser(s) Close barometric condenser and button up drain line Connect pressure transmitters Update REACTOR ISOLATION AND TAGGING CHECKLIST to allow operating valves required for leak check `DTE: Before signing this section the maintenance foreman is required to check the system at the field to verify that nothing has been overlooked. At that time a housekeeping inspection is to be completed b\ the foreman as to correct deficiencies while operators perform the leak check. Notify reactor foreman at the time that you return this form to the lead operator. DATE: TIME: ./ / FOREMAN: NOTE: Operators are to leak check the system according to SOP or special instructions at the time of leak check ___ ,, 16. ------ ,, 17. ------- 18. _____ 13- Leak check per list Notify reactor foreman or maintenance foreman about any leaks. Identify leaks with tags. Leak check completed after all leaks found were fixed Uni ag and deactivate REACTOR I SOLA? I ON' AND TAGGING CHECKLIST NOTE: Signing tlii-. list indicates that there are no leaks SL 021221 and that maintenance can cluiiim .- a i m their outage work DATE: // LEAD OPERATOR: _____ 20. _____ 21. _____ 22. _____ _____ _____ _____ 23. 24. 25. 26. Hook up thermocouples (check proper hookup with L&N Connect charging hose from transporting header to reactor. Verify the s.vstern since there is a difference between #1 reactor and the others. Connect organics feed flow transmitter impulse lines and fill them up with organics Drain reactor vent flowc transmitter impulse lines Insulate system Connect catalyst blowdown hose Finish cleanup of working area NOTE: Signing this list indicates the completion of the reactor total outage meaning that a final inspection was made to ensure the integrity of the system worked on. (All expansion joints were properly lined-up and with cover installed, lines properly supported, all tags removed, etc.) DATE: ____ _ FOREMAN: nr- O SL 021222 IMPORTANT NOTES 1 After removing the vapor lines from the reactor, remove the pressure transmitters block valve. Secure valves to the piping' with a piece of wire. The purpose of the removal is to be able to clean the nozzles. 2. Tag and secure the bayonets drain piping. New piping had to be fabricated during the last two outages because the old one was lost. 1"~ " " 1 considered-finish until the insulation job is completed. (this could be wrapped with temporary insulation) SL 02l223 ni NO. ____ REACTOR TOTAL OUTAGE INSTRUCTIONS: As the system is checked new miscellaneous items will be found that were impossible to be detected earlier. Log: these items on this page, date each item. No modifications desires are to be included on this form. Contact the unit foreman or the maintenance coordinator for improvements or suggestions. PAGE 8 OF 8 SL 02122*