Document evoVwME6V6mBjMopd60zyB2mg

SOP-EDC-VC-L/T STG WRITTEN BY: CSG APPROVED BY: DKP DATE: 10/90 5601-013.SOP DIGITAL ALARMS BACKED-UP ON 03 PLC t r er ou rd C PLC III is set-up to provide back up digital alarms for 36 critical pieces of equipment during computer outages. The moment that the computer gops down, all items on the list below which are in the alarm state will alarm on PLC III and print out on the PLC printer. While the computer is down, if one of The lis 1. 2. 3. 4. 5. 6. 7. a. 9. 10. 11 . 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. #1 .Lights Still condenser #2 .Lights Still condenser #3 .Lights Still condenser *See note 01 #4 .Lights Still condenser #5 .Lights Still condenser .#6 Lights Still condenser Lig.hts Still reflux pump. - +* See note 02 #1 ;Heavy Still condenser fan. #2 .Heavy Still condenser fan. *See note 01 #3 Heavy Still condenser fan. #4 .Heavy Still condenser fan. ^ He a vy Still bottoms pump. - **See note 02 EDC HCL Knock Out Pot Drum level high. #1 Quench Condenser fan. -- #2 Quench Condenser fan. *See note #1 #3 Quench Condenser fan. #4 Quench Condenser fan. #1 Quench Dopp Overhead condenser #2 Quench Dopp Overhead condenser 3 *See note 01 #1 Quench Dopp Kettle agitator. #2 -Quench Dopp Kettle agitator. #1 VCM York Refrigeration compressor trouble. #2 VCM York Refrigeration compressor trouble. 01 Furnace Feed pump. 02 .Furnace Feed pump. 03 Furnace Feed pump. 01 .Process and Storage Refrigeration compressor trouble, 02 Process and Stora ge Refri geration compressor trouble. 01 .EDC Sidearm Cooler fan. 02 C Sidearm Cooler fan. *See note 01 03 C Sidearm Cooler fan. 04 C Sidearm Cooler fan. 01 C Reactor Condenser fan. 02 C Reactor Condenser fan. *See note 01. 03 C Reactor Condenser fan. 04 C Reactor Condenser fan. EDC .Compressor trouble. J*Note * 9 * 'iThose ',it'eihs-'`w&ibjY}lare grouped together are programed ' X 'paralle*!. in' the If any one of the'motors i'n" this group 'go~es down, you will get a general alarm felling you each time that any one of the motors goes down. **Note 2: These pumps are wired so that the digital alarm only sounds when the second or last pump goes down. O t c e ri v t ; No. 91-1145 c ti is e O t ct to P ro ,:vJu(Tic'iic>I C O N F ID E N T IA L I 1u4btjhe SL 004342 S ' f o , ti ! SOP-EDC-OHC-VC-L/T STG WRITTEN BY: PULLEM QAT APPROVED BY: DKP DATE: 10/17/90 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 has been modified for VCM-II. CHECK ACTION STEPS (Capital letters) and Comments (Small letters) i 4J U Wj 3 .4) O t r~> V4 ' O JJ ; O': > VJ --: 44-m u' j ,rr C.1 -- V CZ --t 4J I o r-t <n iTi a. -! o* 0o WCZ 3 *- n o <i> JS 1--1 XI 3 "4 W o 1. IF AN ALARM, INSTRUMENT, OR SHUT DOWN SYSTEM MALFUNCTIONS, THE OPERATOR'S FIRST RESPONSE SHOULD BE AN ATTEMPT TO FIX IT. In every circumstance, the first response should be a reasonable effort toward correcting the cause of the problem. Operating without alarms, instrumentation, or shut down system valves introduces a level of risk that is not desirable. 2. CHECK TO MAKE CERTAIN WHAT PRIORITY THE ALARM, INSTRUMENT, OR CONTROL VALVE FALLS INTO: Check the list of alarms attached in the unit SOP manual to determine what the priority of the alarm is. The priority system to be used is as follows: Pri ori t v 1_ - Critical instruments whose failure would either 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, CD *a- DEQ, Consent Decree), also Operations Review Committee CD (ORC) reliability alarms, and alarms deemed critical *by *3O operations supervision. All of these alarms are ort the proof testing schedule. *. * * . Pri ori t y 2_ - Critical instruments whose failure could eJLther (S) cause or fail to inform of serious conditions involving recordable environmental releases, property or product! i losses, or other non-life threatening situations. \ Thest^ are slightly lower priority alarms which are also'on the proof testing schedule. PAGE 1 OF 4 C0NFIDEKT1AT.I Pri ori t v 3_ - All other alarms, which are not on the prooftesting schedule. For VCM-II, priority 3 includes control valves which are not tied directly into a SOS. Note; Operations will treat priority 1 and 2 alarms j.n an identical fashion. The only reason that these are- differentiated is for the sake of the prooftesting i program. J IF THE ALARM, INSTRUMENT, OR CONTROL VALVE IS PRIORITY 1 OR 2, GO TO STEP #5. IF THE ALARM IS PRIORITY 3, GO TO STEP *3. \ RESPONSE TO PRIORITY 3 ALARMS AND BYPASSED CONTROL VALVES. THE LEAD OPERATOR SHOULD USE HIS KNOWLEDGE OF THE UNIT .TO EVALUATE EACH SITUATION AND MAKE A DECISION AS TO WHETHER THE INSTRUMENT OR CONTROL VALVE CAN BE BYPASSED OR NOT. . .s; ' ' If there is any doubt about this choice, supervision 'should be consulted. These alarms and instrumentation are riot' considered critical under normal conditions. ,,- 4. THE LEAD OPERATOR SHOULD FILL OUT A YELLOW OUT-OF-SERVICE TAG FOR BYPASSED CONTROL VALVES ONLY. A TAG DOES NOT HAVE TO BE FILLED OUT FOR PRIORITY 3 ALARMS. Immediate action is to be taken to initiate repairs on instrumentation. This means at least a note in the maint. logbook so that the problem will not be forgotten. STOP HERE FOR PRIORITY 3 ITEMS. 5. RESPONSE TO PRIORITY 1 OR 2 ALARMS. RCRA, EPA, CONSENT DECREE, OR CRITICAL ALARMS, INSTRUMENTATION OR SHUT DOWN SYSTEM AUTOMATIC VALVES. NOTIFY YOUR LEAD OPERATOR OF THE SITUATION. No one except the unit lead operator or supervisor has the authority to approve taking an alarm out of service. 6 U3 C c u u oF o c. * > w _ 2 * n: O ic W ' y es n * & *.* v X *" 2 o ~^ o~ " .t t* V JZ r"> jJ J2 * 0 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 mOUT-OF-SERVICEm TAG AND MOUNT IT. ON THE CONTROL PANEL. HE WILL ALSO MAKE NOTE IN THE OPERATIONS \ LOGBOOK TO EXPLAIN THE DETAILS OF WHAT HAS BEEN DONE AND WHY i IT WAS NECESSARY. IF, IN THE LEAD OPERATOR'S OPINION, IT IS' NOT SAFE TO DO SO, SUPERVISION SHOULD BE CONSULTED. , The out-of-service tag is intended to be a communications ; tool for notifying other people that Priority 1 or 2 aXaf'mj? J are out of service or a control valve is bypassed. Th&s& tags should be affixed to the instrument on the control , panel or, if this is not possible, in another prominent place on the control panel. These out-of-service tags:'f^ll-l-} remain on the board until the situation is corrected. ;` There are circumstances during routine^ operations when sphCe of these alarms or valves need to be taken out of service for short periods of time to perform short term routine -.work on the system. Some examples of this include the following: PAGE 2 OF 4 t c r di rd e `t? IM ,: Ti.i'-nti ivi*c 0- VJ.-IH3 I-l-'iirclstPC L V tfl'J P 'iS T to iiiti.O t J e ll tbi Suu f o (1 ) . Pulling alarm cards at EDC 1 to look for a "mystery alarm". (2). Taking alarms out of service on the computer at VCM^^, II long enough to identify them on the CRT display (3). When an operator and log hook instrument man go outside to look at a shut down system valve that is sticking. (4). When OHC analyzers are bypassed for preventive maintenance work. Under- these and' other similar circumstances it would not normally be worth the 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 met: 1) The lead operator is informed of the situation and gi ves approva1. 2) The operator gives undivided attention to this problem. If both of these cannot be met, then the out-of-service tag must be used regardless of the length of time reguired for the work to be done. The out-of-service tags are not a substitute for performing maintenance... , The out-of-service tags serve only to communicate the status of instruments in need of repair. 8. TAKE IMMEDIATE ACTION TO INITIATE REPAIRS ON THE OUT-OF SERVICE INSTRUMENT. ) 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. On day shift this may require redirecting the maintenance logbook priorities, or notifying supervision so an "Emergency" work order can be written. On the back shifts and during holidays, this may mean notifying the shift supervisor to get shift mechanics or call out instrument mechanics so that the repairs can be made in a timely fashion. In either case it is strongly recommended that repairs be started as soon as practical. Ordering "Out-of-Service" tags. These tags are set up in our reproduction department with a form number (59A-6) so that day shift operators can reorder these by telephone. 9. .10 T~ 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 FROM THE BOARD, TAPE IT INTO THE LOGBOOK, AND COMPLETE THE BOTTOM ' SECTION OF THE OUT-OF-SERVICE TAG. " .. ` A WEEKLY OUT-OF-SERVICE TAGGING CHECKLISTm WILL BE COMPLETED BY EACH UNIT ON MONDAY MORNING GRAVEYARD SHIFT TO CONFIRM THAT THE PANEL ALARMS AND LIGHTS ARE IN WORKING ORDER AND THAT ALL OF THE OUT-OF-SERVICE ALARMS, INSTRUMENTATION, ANU^ CONTROL VALVES HAVE BEEN PROPERLY TAGGED ACCORDING TO THIS SOP. THE UNIT FOREMAN FILE THESE CHECKLISTS TO MAINTAIN A RECORD IN THE EVENT OF AUDITS BY ENVIRONMENTAL AGENCIES. SL 004345 PAGE 3 OF 4 The objective of the weekly checklist is to routinely take an inventory of the out-of-service tagging which has been done and to correct all tagging deficiencies on the spot. Each individual unit will make up a detailed checklist which will be entitled "Weekly Out-of-Service Tagging Checklist". During this weekly inventory, the audible and visual alarms should be proven to be in working order. A check of all of 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 step #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 AND AREA SUPERVISOR, INITIALLED, AND MAILED WEEKLY TO THE DERIVATIVES ENVIRONMENTAL FOREMAN. SL 004346 PAGE 4 OF 4